A lamination model for forming simulation of woven fabric reinforced thermoplastic prepregs

In order to characterize the large deformation, anisotropy and multi-field coupling behaviors of woven fabric reinforced thermoplastics (WFRTP) in forming, a lamination model combining thermoplastic resin and woven fabric reinforcements is established. The WFRTP is modeled as a laminated structure with impregnated woven fabric layers sandwiched between two thermoplastic resin layers. The thermo-mechanical coupling and viscosity resulted from melted resin matrix is characterized by an isotropic visco-hyperelastic model, while the impregnated woven fabric reinforcement is defined by an anisotropic hyperelastic model. The proposed lamination model is demonstrated on forming simulation of a WFRTP over a double-curvature mold. The effects of processing parameters including forming temperature and blank holder force on wrinkling are investigated. The proposed model is simple and easy for material parameter determination. It provides a theoretical foundation for numerical simulation and processing optimization of WFRTP forming.