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<p>With the rise in popularity of high-performance composites, the need to fabricate these materials with minimal defects has become crucial for both environmental and economic reasons. One of the most critical defects in composite forming is wrinkling, which often occurs when prepregs are used to produce doubly curved parts. This defect can lead to material waste and increased energy consumption during production. In this work, a novel forming method is introduced to form composite laminates directly on the tool surface, enabling the buildup of multiple thin laminates to the desired thickness while minimizing the occurrence of wrinkles and, consequently, reducing potential material waste. The method modifies the double-diaphragm forming process by replacing one of the diaphragms with an easily removable inflatable tube placed adjacent to the composite part, covering the area prone to wrinkling. This setup provides pressure on both sides of the laminate, effectively preventing wrinkle formation. The results showed minimal thickness variation, with an average thickness of 2.15&#xa0;mm and a standard deviation of 0.08&#xa0;mm. Additionally, the lightweight nature of the composite parts produced by this method holds significant potential for fuel savings in the aerospace and automotive industries, where weight reduction is directly linked to improved fuel efficiency and reduced emissions.</p>

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Forming Wrinkle-Free Curved C Channel with Unidirectional Fiber Reinforced Composites

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年2月14日

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  • Suk Young Chey,
  • Sung-Hoon Ahn

摘要

With the rise in popularity of high-performance composites, the need to fabricate these materials with minimal defects has become crucial for both environmental and economic reasons. One of the most critical defects in composite forming is wrinkling, which often occurs when prepregs are used to produce doubly curved parts. This defect can lead to material waste and increased energy consumption during production. In this work, a novel forming method is introduced to form composite laminates directly on the tool surface, enabling the buildup of multiple thin laminates to the desired thickness while minimizing the occurrence of wrinkles and, consequently, reducing potential material waste. The method modifies the double-diaphragm forming process by replacing one of the diaphragms with an easily removable inflatable tube placed adjacent to the composite part, covering the area prone to wrinkling. This setup provides pressure on both sides of the laminate, effectively preventing wrinkle formation. The results showed minimal thickness variation, with an average thickness of 2.15 mm and a standard deviation of 0.08 mm. Additionally, the lightweight nature of the composite parts produced by this method holds significant potential for fuel savings in the aerospace and automotive industries, where weight reduction is directly linked to improved fuel efficiency and reduced emissions.