Inter-ply stitching optimisation of highly drapeable multi-ply preforms

An efficient finite element model has been developed in Abaqus/Explicit to solve highly non-linear fabric forming problems, using a non-orthogonal constitutive relation and membrane elements to model bi-axial fabrics. 1D cable-spring elements have been defined to model localised inter-ply stitch-bon...

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Bibliographic Details
Published in:Composites. Part A, Applied science and manufacturing Applied science and manufacturing, 2015-04, Vol.71, p.144-156
Main Authors: Chen, S., Endruweit, A., Harper, L.T., Warrior, N.A.
Format: Article
Language:English
Subjects:
A. Fabrics/textiles
Computer simulation
Criteria
E. Forming
E. Preform
E. Stitching
Forming
Mathematical models
Optimization
Preforms
Shear
Stitches
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Summary:An efficient finite element model has been developed in Abaqus/Explicit to solve highly non-linear fabric forming problems, using a non-orthogonal constitutive relation and membrane elements to model bi-axial fabrics. 1D cable-spring elements have been defined to model localised inter-ply stitch-bonds, introduced to facilitate automated handling of multi-ply preforms. Forming simulation results indicate that stitch placement cannot be optimised intuitively to avoid forming defects. A genetic algorithm has been developed to optimise the stitch pattern, minimising shear deformation in multi-ply stitched preforms. The quality of the shear angle distribution has been assessed using a maximum value criterion (MAXVC) and a Weibull distribution quantile criterion (WBLQC). Both criteria are suitable for local stitch optimisation, producing acceptable solutions towards the global optimum. The convergence rate is higher for MAXVC, while WBLQC is more effective for finding a solution closer to the global optimum. The derived solutions show that optimised patterns of through-thickness stitches can improve the formability of multi-ply preforms compared with an unstitched reference case, as strain re-distribution homogenises the shear angles in each ply.
ISSN:1359-835X
1878-5840
DOI:10.1016/j.compositesa.2015.01.016