Experiment Study of Thermoforming of Plain Woven Composite (Carbon/Thermoplastics)

Abstract

By combining carbon woven fabric with thermoplastics grains, a thermo-stamping process is proposed for forming parts with complex double curvatures in one step, to implement the affordable application of fiber reinforced composites in high volume merchandises such as automotive industry. In the proposed thermo-stamping process, laminated carbon woven fabrics with thermoplastic grains are heated, and then transferred rapidly to a preheated mould for thermo-stamping, and cooled down to form the carbon fiber reinforced composite part. Various thermoplastics such as PP, PA6 and ABS are used as matrix material in the composite part. Experimental results including shear angle distribution in the fabric, deformed boundary profile of fabric with different original fiber orientation and forming defects are presented. It is demonstrated that high quality parts can be obtained with the proposed forming process, and defects are controllable. By using the proposed process and laminated structures, it is feasible to implement the high-volume and low-cost manufacturing of fiber reinforced composite parts.