Parameter Study and Optimization of Forming Simulations for Tape-Based Fiber Layups

Abstract

AbstractThis work presents a model of a parametrized fiber-reinforced tapes layup for simulations of stamp forming. BETA CAE Systems’ ANSA v22.1.0 produced the forming model. The initial configurations of the forming process are simulated using LS-DYNA R12 from the Livermore Software Technology Corporation (LSTC) on the High-Performance Computing Center Stuttgart (HLRS). A doubledome geometry was used as a use case in the presented study. An optimal solution is found by predicting and analyzing the forming defects, both quantitatively and qualitatively. Typical defects induced by the forming process include wrinkles, bridging, waviness, misalignment of tapes, instabilities due to tape overlaps and gaps, etc. Adjustments to the forming process are made by varying model parameters such as stacking sequence, fiber angle, material properties, tape orientation, or the position of ultrasonic thermal bonds between tapes. In addition, process parameters such as tool velocity, temperature, and gripping force were considered. Different algorithms for the sample creation of the designed experiments are examined, and the influence of various parameters on the final part is discussed. The limitations and requirements of the employed software are examined for additional studies. Furthermore, the machine learning-based neural network algorithms discussed, such as particle swarm optimization (PSO), gradient-based optimization (GBO), response surface method (RSM), and genetic algorithms (GA), may be used in future research to determine an ideal tape arrangement for various geometries based on nodal locations and the parameters as mentioned above.