Entwicklung einer Methode zur Formsimulation faserverstärkter Thermoplaste

Fabric-reinforced thermoplastics are used for lightweight parts within automotive components. They can be formed using thermoforming processes after heating above the melting temperature of the thermoplastics. The fiber angles and the wrinkling of the final parts influence the mechanical properties. Thus, there is a great interest in the development and improvement of simulation methods for the prediction of fiber angles and wrinkling. The present work focuses on the development of an FE model to represent the forming behavior of fabric-reinforced polyamides and polypropylene with ABAQUS/EXPLICIT and the implementation of material tests for the shear, tensile, compressive and bending stiffnesses at forming temperature within a heating chamber. Currently, there is no standardization for the material tests. To validate the model, forming tests of a double dome demonstrator are carried out on a press and the fiber angles and wrinkling of the final parts are measured. This includes the development of a program to determine the fiber angles of the components and samples of the material tests. The influence of the individual input parameters of the material cards and their interactions are examined using sensitivity analyzes of the FE model. On this basis, a holistic method for the forming simulation of fiberreinforced thermoplastics is being developed. The method includes the determination of material parameters and their implementation into the FE model up to the forming simulation of the component. Finally, the method will be validated within the simulation of a bumper cross member.