Finite Element Method Based Simulation and Validation of Draping Strategies for the Development of an Automated Preforming Process (Masterarbeit)

Abstract

The center for Lightweight Production Technology in Augsburg is involved in the developing of an automation concept for the preform production of an Aero Flap Support (AFS). As a part of this project, the current thesis investigates the draping effects of carbon fiber non-crimp fabrics on the AFS Tooling. Simulation software packages based on two different draping techniques are employed to perform the draping simulation and develop the draping strategy; ANSYS Composite PrePost (Kinematic Mapping Approach) and PAM-FORM (Finite Element Approach. An extensive material characterization of the fabrics by means of the picture frame test, the friction and the bending test are performed in order to generate required data to execute the simulation. The goal of the simulations is to obtain a near net shape flattening or flatwraps of the plies and to predict and investigate shearing of the plies that might lead to defects such as fiber wrinkling. The flattening and shear angle results from the simulation are validated against manual draping tests. The material characterization, simulation results and the validation are presented in this thesis.