M.F Hot Drape Formingb
M.F Hot Drape Formingb
NAME ID NUMBER
KASSAHUN FERDA 038/15
SUBMITTED TO: A.PROFESSOR ASMAMAW
Addis Ababa-Ethiopia
DECEMBER
2023
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Table of Contents
Hot Drape Forming Analysis of Thermoset Materials..................................................................................................................2
1. ABSTRACT..........................................................................................................................................................................2
2. INTRODUCTION.................................................................................................................................................................3
3. Experiment............................................................................................................................................................................6
3.2 Methodology.....................................................................................................................................................................7
3.2.2 Design of Experiment...................................................................................................................................................8
3.2.3 Experimental Method..................................................................................................................................................10
4. Results and Discussion........................................................................................................................................................14
5. Mechanical Testing.............................................................................................................................................................22
6. Conclusions.........................................................................................................................................................................24
7. References...........................................................................................................................................................................26
1
Hot Drape Forming Analysis of Thermoset Materials
1. ABSTRACT
understanding of how processing these materials leads to potential defects still needs to
be fully characterized. This paper investigates the effect of forming temperature, ply
count, fiber type, and fabric type on out-of-plane wrinkle development for a hot drape
understand the effect that the wrinkle size has on mechanical properties. Influential
parameters were identified as the forming temperature affecting the resin viscosity, the
weave type, and the fiber type. A decrease of the resin viscosity reduced the generated
wrinkles. This is attributed to the improved interlaminar slippage with lower viscosity.
The same effect was also observed with increased fiber twist. The 8 harness weaves
the ply count increases the complexity and thus the likelihood of wrinkle formation but
was not identified as a driving factor for wrinkles. The results show that the primary
influencing factor of hot drape forming is the interlinear slip. Mechanical tests were
also performed and showed that wrinkles with an L/D less than 10 create a large
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2. INTRODUCTION
The use of advanced carbon fiber reinforced polymer composite materials has
expanded widely in the past decade specifically in the aerospace industry. The high
stiffness-to-weight ratio, fatigue resistance, and damage tolerance make carbon fiber
composites suitable for either military or large civil aircraft. One of the most important
ensure there are no compromises in structural integrity. Boeing 787 and Airbus A350,
for example, contain such carbon fiber composites in approximately 50% of their
The assembly with mechanical fasteners adds both cost and weight to the structure.
One way to reduce the complexity and weight is to integrate a number of parts into one,
traditionally been done by hand lay- up. Due to the increase in the number of
composite parts that are being used in the build- up of aircraft components (and also
because of the large scale of these parts), hand lay-up can be both time consuming and
costly. This has led to an increased focus on automation processes such as Advanced
Fiber Placement (AFP) or Automatic Tape Lay (ATL) in combination with multi-layer
forming.
The process by which a composite part is manufactured can be divided into three
phases: lay-up, forming, and cure-assembly. The forming phase of complex geometries
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Can be extremely difficult and can result in defects (such as wrinkles) during the process.
Wrinkles can impact the structural integrity of a part. It has been shown that out-of plane
The forming process can be achieved through a variety of forming processes such as
forming is Hot Drape Forming (HDF). Where a prepare lay-up is placed on a mold,
heated to a temperature below the curing temperature and formed down to the mold with
a rubber diaphragm using vacuum [4]. Figure 1 shows a schematic of the process.
It has been shown that the forming process generally depends on multiple material
specifics and inherent mechanisms, such as locking angle, interplay shear, ply bending,
given to understand the overall material behavior. In addition, the use of computer
modeling is necessary to define the optimal set of process parameters to avoid the
production of inferior parts. Through models and small scale experiments, many authors
friction
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or tack, locking angle, and ply thickness all have been reported to affect wrinkle
initiation in a variety of processes. Many of these parameters (e.g., tack and interplay
Other parameters, such as the locking angle, can influence how the in-plane deformation
affects the shapes to which a material can adopt. High locking angles typical of PW
fabrics have less conformability than do the lower locking angles of 8HS.
Process parameters that have been identified as influencing defect initiation are: form
temperature, form rate, form pressure, and initial contact point of the laminate. Even the
geometry of the part (such as the tool radius, joggles, ply drops, and laminate thickness)
articles because they possess all of the aforementioned geometries as shown in Figure 2.
In a series of unidirectional tape laminates were hot drape formed into a c-channel
geometry incorporating a joggle which is the change of web height along the length of
the c-channel. The joggle is outlined in Figure 2. It was shown that localized
5
This paper further advances the work presented in and addresses how the drivability of
between resin viscosities, ply count. and out-of-plane wrinkle magnitude. Two thermoset
material systems with three different weave typesuni-directional, plain weave, and 8H
fabrics are investigated herein.In addition, mechanical testing are performed on samples
taken from the cured c-channel part in order to quantify the impact of wrinkle on tensile
3. Experiment
3.1 Materials
Two resin systems were tested in this experiment, Cycom 970 (Solvay) and Cycom
5320-1 (Solvay). Both resins are an epoxy; system 970 is a 350 °F cure autoclave system
while 5320-1 is an out-of-autoclave material 250 °F cure with 350 °F post cure. Two
different fiber twists were evaluated to show the effect of interply shear. Both standard
twist fiber (with 5 twists per inch) and never-twisted fibers were used in the tests and the
results compared. The manufacturer reports that the interlaminar shearing ability of
never twisted fibers is greatly superior to that of the standard twist material. Several
different weave patterns from T650 fibers were investigated as outlined in Table 1.
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Figure 3 shows surface images of the several green prepregs. The prepregs are fully
impregnated. The weaves (b & c) show that the resin primarily consolidates at the tow
junctions.
a b
Samples tested were within the manufacture’s recommended working life of 10 days and
3.2 Methodology
Material formability was tested using one tool geometry outlined in Figure 4.
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Figure 4: Test tool geometry in x and y directions
The tool had two symmetric joggles and radii of 0.25 inch. Table 2 provides additional
The double joggle and joggle instep can create a challenging feature to drape form.
During forming, the laminate will follow a geodesic curve. Bending occurs on the tool
side ply, and interlinear shearing occurs as the remaining plies conform to the tool
geometry. The double joggle feature aggressively reduces the cross-sectional perimeter
of the c-channel making it an ideal test specimen. As described in this reduction creates
tensile and compressive stresses in the joggle region which can induce out-of- plane
wrinkles. However, with sufficient interlinear shearing, the plies are able to sufficiently
For each material type, a quasi-isotropic layup was used, as presented in Table 3. For the
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Table 3: Layup for fabric types
varied 4 variables: ply temperature, ply count, fabric type, and fiber twist. The
replicates performed for each c-channel, as well as the resin viscosity from the
Test Resin
Resin Fabric Ply
Temperature Viscosity Replicates
System Weave Count
(F) (poise)
970 Uni 18 140 1500 2
970 PW-ST 10 140 1500 1
970 PW-ST 18 120 3000 2
970 PW-ST 18 140 1500 1
970 PW-ST 30 72 22000 1
970 PW-ST 30 100 6500 1
970 PW-ST 30 120 3000 1
970 PW-ST 30 140 1500 2
970 PW-ST 30 160 650 1
970 PW-ST 30 180 350 1
970 PW-NT 30 72 22000 1
970 PW-NT 30 100 6500 2
970 PW-NT 30 120 3000 2
970 PW-NT 30 140 1500 1
970 PW-NT 30 160 650 1
5320-1 Uni 18 125 90 2
5320-1 PW 18 125 90 1
5320-1 8H 18 125 90 2
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3.2.3 Experimental Method
The experimental setup as well as the tool geometry for this study, are shown in
Figure 6. Flat composite laminates were fabricated based upon the layups provided in
Table 3. Each laminate was placed on the tool (Figure 6B) and heated. Laminate
flange. Once the laminate reached the desired temperature, vacuum was pulled and held
until the charge cooled to room temperature. Green state wrinkles were characterized
based upon both tool location and size, as depicted in Figure 7. The maximum height,
wrinkle wavelength, and out-of-plane wrinkle depth were measured. The ratio of
wavelength/depth (L/D) represents the out-of- plane wrinkle magnitude and is used in
analysis. A low L/D (i.e., LD < 10) represents a large green state wrinkle, which heavily
influences mechanical properties. A large L/D (i.e., L/D > 100) is a minimal green state
wrinkle which is likely to be mitigated during cure. Formed wrinkles were classified into
three groups: Span, Chord, and Off-Angle. Span wrinkles occur along the length axis of
the c-channel while chord wrinkles occur perpendicular to the length. Off-angle wrinkles
are a combination of chord and span wrinkles. These wrinkles are at some angle greater
than 0° but less than 90° referenced from the long axis. The three wrinkle types are
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Figure 5: Wrinkle Types
Figure 6: Hot drape forming setup: (A) Hot drape forming apparatus - (B) Composite laminate on tool
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Figure 7: Wrinkle size measurements
Several 970 PW-ST c-channels were cured using the manufacture’s recommended cure
cycle shown in Figure 8. Micrograph and tensile test specimens were taken from the
cured wrinkle zones in order to evaluate the effect of the wrinkle on the tensile structural
behavior. To fully capture the effect of cured wrinkles, a non-standard test method was
used to test various size samples. These samples were cut at various lengths because the
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Table 5 shows the details of the specimens used for the mechanical testing. Unnotched tension tests (UNT)
were considered for this work.
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Table 5: Specimen dimensional detail
The specimens were placed into a hydraulic wedge grip, and load was applied until
failure. Note that the specimens were sanded near the edges in order have an even
surface for grip attachment. The main purpose of the tensile tests was to evaluate the
load reduction as function of wrinkle size and to get a preliminary understanding of the
relation between wrinkle size and tensile behavior and was not intended to find the
ultimate tensile load of the composite. All samples were tested at a constant
Chord wrinkles formed on the web and the flange of the PW fabric c-channels shown in
Figure 9, and off-angle wrinkles only on the flange of the unidirectional tape material as
shown in Figure 10. No span wrinkles were observed in any c-channel. Off-angle
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wrinkles were formed on the unidirectional tape c-channels, shown in Figure 10, and the
room temperature PW c-channels. These wrinkles are caused by the zero oriented fibers
bridging over the joggle recess due to an inability for plies to slip. The wrinkles were
eliminated when the resin viscosity was increased in the PW trials. The plain weave
fabrics exhibited chord wrinkles at the base of the flange shown in Figure 9. These
wrinkles were not observed, however, in the 8 harness weave. Figure 11 shows the result
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Figure 11: Post forming of c-channels for 8H material
The PW flange chord wrinkles formed at the inset of the joggle as shown in Figure
12. The change in area at the joggle creates regions of compression in the laminate,
which induces the ply bucking. Chord web wrinkles also were observed in several PW c-
channels. It is challenging to identify the root cause of these wrinkles because several
factors influence the formation of these wrinkles, as was observed through the testing and
outlined herein. Excess sagging from the transfer of the charge onto the tool was
observed to correlate with the web wrinkle locations. Additionally, material defects e.g.,
individual ply wrinkles observed toward the end of the material roll Figure 13 also can
induce web wrinkles even when these wrinkle are worked out during layup. Additionally,
web wrinkles occurred in all room temperature tests indicating that the process has an
many external factors (and because a sufficient process was not developed to negate
these factors), the web wrinkles are only reported in the results and not further discussed.
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Figure 12: Wrinkle generation of 970 resin PW tests
cases of the cycom 970 30 ply samples tested at either 160 or 180 °F) no wrinkles
occurred in the c-channels. Due to the tolerance of the wrinkle depth measurements,
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Resin Fabric Ply Temperature Wrinkle Wrinkle Average Average Average Average
System Weave Count (F) Location Type H L D L/D
From these data, four comparisons can be made. Among the Cycom 970 PW-ST tests
both the effect of resin viscosity (temperature) and the number of plies can be shown.
The effect of ply slip can be observed by comparison of the Cycom 970 PW-ST
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with the PW-NT. The effect of material weave pattern can be observed in the Cycom
5320-1 samples.
Study of the 970 system samples with a ply count of 30, indicates that the effect
of the resin viscosity on wrinkle development can be evaluated. Figure 14 shows the
observed that, as the viscosity decreases, the magnitude of the wrinkle also decreases
(increasing L/D). The data shows that there is a “sweet spot” for forming in order to
reduce the magnitude of wrinkles. For PW-ST, that viscosity occurs between 3000 and
6500 poise.
Consideration of the differences in wrinkles due to fiber twist reveals that the
never twisted fiber has superior forming properties over standard twist fibers. This is
likely a result of the reduced interlaminar shearing within the NT laminate compared to
the ST laminate. It is interesting to note that, at room temperature, the resulting wrinkles
between the ST and NT tests are similar. This indicates that other material properties
dominates at higher temperatures. It is theorized that the tack of the prepreg may
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Figure 14: Effect of 970 resin viscosity on wrinkle L/D
The number of plies affects the forming as well as the wrinkling. The 970 system
PW-ST fabric at 140 °F shows that as the ply count increases, the magnitude of the
wrinkles also increases. The 10 ply charge possessed very small wrinkles, averaging
0.001 inch in depth, which would dissipate under debulk. Therefore, these cracks are
inconsequential. The 18 ply charge possessed one wrinkle in the flange with an L/D of
15.4. While this wrinkle would not dissipate during debulk it was less pronounced than
the 11 wrinkles in the 30 ply charges with L/D’s ranging from 5 to 200. As ply counts
increase, the total necessary force to deform a laminate also increases. The 30 ply
laminate had insufficient vacuum force to induce interply shear, which transferred the
load into the laminate and created compressive stresses leading to wrinkle development.
These results further support the work performed by Hallander, et al. [18], which showed
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4.1.3 Effect of weave type
The 5320-1 system c-channels were all formed at 125 °F and 18 plies. The UD
c-channel exhibited wrinkles on the web and the flanges. The flange wrinkles included
both off-angle and chord wrinkles. The chord wrinkles occurred at the inset of the
joggle, while the off-angle wrinkles spanned the joggle region. The existence of off-
angle wrinkles indicates that the double joggle geometry was too aggressive to allow for
the use of unidirectional tape. The 0 oriented fibers bridged the joggle recesses and were
unable to shear causing the wrinkles. Fabric weaves exhibit a pinned joint enabling small
angle deformation, reducing the zero bridging, and successfully eliminating the off-angle
wrinkles.
The chord flange wrinkles occurred at the onset of the joggle. The magnitude of
these wrinkles degreases with increasing deformability of the harness type, as shown in
Figure 15. The UD tape resulted in the largest wrinkles. The PW fabric reduced the size
of the wrinkles as compared to the UD tape; but it did not eliminate them completely.
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These results show that in-plane shear of the material greatly affects the out-of-
plane wrinkles. The increased locking angles of the 8 harness satin material allowed the
These results show that out-of-plane wrinkles are influenced by the weave type in
Through these experiments, it was identified that the resin viscosity affects the
size of out-of-plane wrinkles. Both lower viscosities and increased forming temperature
reduce the size of the wrinkles. Fiber twist also has an effect. The never twisted material
is able to slip more easily than does the standard twist material. As a consequence, it can
produce wrinkle free parts at much lower temperatures than can the standard twist
material. It was shown that increasing the ply count increases the complexity of the part,
which increases the number of wrinkles observed. Furthermore, weave type influences
the out-of-plane wrinkles with the highly deformable 8HS producing no wrinkles.
5. Mechanical Testing
samples were taken in order to perform tensile testing for evaluation of the effect of
wrinkle on the tensile behavior. Web wrinkles from the room temperature 970 system c-
channel were subjected to a non-standard tensile test with coupons of various sizes, as
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Figure 16 - Test specimens cut from the c-channel:
4 specimens with wrinkles (A-D) and 4 specimens without wrinkles (E-H)
in order to observe the waviness of the plies and the deformation due to the wrinkle
defect, as shown in Figure 17. It is clear from the micrographs that the wrinkles
originated on the tool side of the laminate and carried through the laminate to form a
The results of the tensile tests are shown in Figure 18. The results are reported as
a percentage change with respect to a wrinkle free laminate. The results show that a
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cured L/D less than 10 significantly reduces the tensile performance of a laminate, while
1.2
1
Tensile Strength Correction Factor
0.8
0.6
0.4
0.2
0
0 2 4 6 8 10 12 14 16
Wrinkle L/D
From these results, it should be noted that defects (such as wrinkles) generated during the
forming process can have a significant impact on the structural performance of a part.
This can be done either by determination during the design phase as to what size wrinkles
6. Conclusions
This paper discusses the formability of two different resin systems namely Cycom
970 (Solvay) and Cycom 5320-1 (Solvay) with various weaves. The effect of forming
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temperature, ply count, fiber type, and fabric type on out-of-plane wrinkle development
was investigated. It was observed that magnitude of wrinkles decreases as the resin
viscosity decreases or forming temperature increases. The never twisted material is able
to slip more easily than the standard twist and thus can be used to achieve wrinkle free
parts at much lower temperatures than can be obtained with the standard twist material.
Moreover, increase of the ply count increases the likelihood of wrinkle formation. The
fabric weave type also plays an integral part of the forming. The weaves performed
better than did the unidirectional fabric due to the relatively small angle deformation that
each ply can endure before wrinkling. Mechanical tests were performed on cured
wrinkles, and it was observed that the wrinkles had an impact on the tensile performance
depending on the wrinkle L/D value. Thus, in order for the industry to decrease the
techniques by fully characterizing and understanding material systems. Future work will
investigate characterization of the intraply and interply shearing of the various fiber
types and correlate how these parameters affect wrinkle development in hot drape
forming processes.
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7. References
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doi:10.1016/j.compositesa.2011.04.010.
complex shape parts in composite material. Int J Adv Manuf Technol 2015.
doi:10.1007/s00170-015-7998-x.
doi:10.1201/9781439824344.
European Congr. Comput. Methods Appl. Sci. Eng. E-b. Full Pap., 2012, p. 8094–
104.
simulation of the draping process of multilayer knit structures and the effects of a
doi:10.1080/09243046.2013.791239.
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