<p>Reliable prediction of post-demolding deformation is important in composite forming. Layer-wise finite-element models can provide such prediction accuracy, but their computational cost becomes a major concern for large composite structures. To reduce this cost, a through-thickness partitioned homogenization strategy is proposed for composite forming simulation. In this strategy, the thickness of a carbon fiber-reinforced thermoplastic cross-ply laminate is divided into several partitions, and each partition is represented by a homogenized block with equivalent thermo-mechanical properties. Four categories of through-thickness partition configurations are first defined for an asymmetric hot-pressed laminate, and their prediction accuracy and total computational time are then evaluated against a layer-wise benchmark model. The results show that global through-thickness equivalence provides the lowest computational cost but cannot deliver reliable residual-deformation prediction. By contrast, retaining surface plies on both laminate surfaces is strongly associated with physically reasonable predictions, and retaining two surface plies on each side provides a practical balance between prediction accuracy and computational cost. After the bilateral surface arrangement has been fixed, relatively balanced and relatively symmetric thickness-wise layouts are preferred when further repartition is required. Based on these results, two representative implementation routes are selected for engineering demonstration on a variable-thickness composite wing-skin component. Compared with the layer-wise benchmark model, the two routes maintain low prediction deviations, with normalized root-mean-square deviation values of 3.7% and 2.4%, while reducing the total computational time by 87.4% and 75.8%.</p>

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Through-Thickness Partitioned Homogenization Strategy for Composite Forming Simulation

  • Yang Liu,
  • Renyu Hou,
  • Qi Wu,
  • Yanfeng Wang,
  • Ran Huo

摘要

Reliable prediction of post-demolding deformation is important in composite forming. Layer-wise finite-element models can provide such prediction accuracy, but their computational cost becomes a major concern for large composite structures. To reduce this cost, a through-thickness partitioned homogenization strategy is proposed for composite forming simulation. In this strategy, the thickness of a carbon fiber-reinforced thermoplastic cross-ply laminate is divided into several partitions, and each partition is represented by a homogenized block with equivalent thermo-mechanical properties. Four categories of through-thickness partition configurations are first defined for an asymmetric hot-pressed laminate, and their prediction accuracy and total computational time are then evaluated against a layer-wise benchmark model. The results show that global through-thickness equivalence provides the lowest computational cost but cannot deliver reliable residual-deformation prediction. By contrast, retaining surface plies on both laminate surfaces is strongly associated with physically reasonable predictions, and retaining two surface plies on each side provides a practical balance between prediction accuracy and computational cost. After the bilateral surface arrangement has been fixed, relatively balanced and relatively symmetric thickness-wise layouts are preferred when further repartition is required. Based on these results, two representative implementation routes are selected for engineering demonstration on a variable-thickness composite wing-skin component. Compared with the layer-wise benchmark model, the two routes maintain low prediction deviations, with normalized root-mean-square deviation values of 3.7% and 2.4%, while reducing the total computational time by 87.4% and 75.8%.