Path Definition for Tailored Fiber Placement Structures Using Numerical Reverse Draping Approach

Abstract

The properties of fiber reinforced materials are depending on the fiber direction. During draping processes - which are necessary to form complex structures - the fiber direction and therefore the resulting properties of the final part are changing.To ensure that the fibers in the final complex structure are placed exactly in the direction needed, a new approach is investigated.The idea is to define the orientation of the reinforcement fibers based on the distribution of forces in a complex structure under certain loading determined by a structural simulation. Best lightweight behavior is achievable in the final complex structure. A three-dimensional mesoscopic model of the directed fibers is created using FEM-software. In reverse draping simulations the three-dimensional fibers are formed from complex shape to a two-dimensional flat sheet.In manufacturing the two-dimensional patches can be created using the tailored fiber placement process. With this process it is possible to place the fibers orientated to the required paths. The patches are formed to the necessary three-dimensional shape by a real draping process. The relative sliding behavior of crossing fibers can be achieved by varying the stitch during the TFP process.Using that approach it is possible to create lightweight structures in which fibers are orientated directly along the load paths of the three-dimensional application.