Prediction of forming effects in UD-NCF by macroscopic forming simulation – Capabilities and limitations

Abstract

Unidirectional non-crimp fabrics (UD-NCF) provide the highest lightweight potential among dry textile materials. Compared to multiaxial NCF, the fabric layers in UD-NCF enable a more targeted tailoring. Compared to woven fabrics, the fibres of UD-NCF are straight without weakening undulations. However, the formability of UD-NCF is more challenging compared to woven fabrics. The yarns are bonded by a stitching and the deformation behaviour highly depends on this stitching and on the slippage between the stitching and the fibre yarns. Moreover, distinct local draping effects occur, like gapping and fibre waviness, which can have a considerable impact on the mechanical performance. Such local effects are particularly challenging or even impossible to be predicted by macroscopic forming simulation. The present work applies a previously published macroscopic UD-NCF modelling approach to perform numerical forming analyses and evaluate the prediction accuracy of forming effects. In addition to fibre orientations and shear angles, as investigated in previous work, the present work also provides indication for fibre area ratios, gapping, transverse compaction and fibre waviness. Moreover, the prediction accuracy is validated by comparison with experimental tests, where full-field strains of inner plies are captured by prior application of dots onto the fibre yarns, by measuring them via radiography and applying a photogrammetry software. The modelling approach provides good prediction accuracy for fibre orientations, shear strains and fibre area ratio. Conversely, normal fibre strains, indicating fibre waviness, and transverse strains, indicating gapping, show some deviations due to the multiscale nature of UD-NCF that cannot be captured entirely on macroscopic scale.