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Contents
Why test? Deformation mechanisms Data required for forming simulations Available test methods Focus on intra-ply shear testing
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Why test ?
To determine formability of material To assess effects of process variables on forming To determine input data for simulations To validate simulations
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Deformation mechanisms
Textile composites
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Input data required: Start point & initial ply orientation Locking angle
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Input data required: Intra-ply shear modulus Matrix model viscosity (vs temp, rate) Ply/tool & ply/ply friction (vs temp, rate, pressure) Fibre moduli & ply bending stiffness Thermal properties
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KES-FB3: Compression
Energy for compression to 50gf/cm2
KES-FB4: Friction/Roughness
Coefficient of friction with steel wire Surface roughness (mean thickness variation)
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Clamping plate
Le We We Le
Bearings
Fe
Fe
Picture frame
Bias extension
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Yarn
1 direction free
weft K= warp
Strain (%)
0 .5 D form ation (% )
0 .7 5
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Heated Platen
Heated Platen
Side clamp
0.040 Shear Stress (MPa) 0.035 0.030 0.025 0.020 0.015 0.010
0.5mm/s 180C 0.5mm/s 220C 0.8mm/s 200C 1.2mm/s 180C 1.2mm/s 220C
0.005 0.0
0.5
2.5
3.0
Bias extension
Key points: Aspect ratio (Length/Width) should be >=2 Very good way to determine locking angle (central region stops shearing) To find shear compliance, must video test & measure shear angle
Shear Angle
80 70 60 50 40 30 20 10 0
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Force (N)
100
P800200 glass plain weave Specimen width 156mm (2:1 A.R.) 150 Rate = 100mm/min
100
80
50
0 0 10 20 30 40 50 60 70 80 90
60
70
Displacement (mm)
40
Shear Angle (deg)
60 50 40 30 20 10
20
0 0
10
0 10
20
20 30 40
30
50 60
40
70 80
50
90
60
70
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y
140mm
145mm
(a) Specimen
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P800
500
S800-02 T800
400
300
200
100
0 0 10 20 30 40 50 60 70
400 80 300
P800 - 200 N
P800 - 400 N
P800 - 800 N
Dry fabrics: No rate effects In-plane tension affects compliance & locking
200
0 0 10 20 30 40 50 60 70
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Ebx936 Parallel
500
Ebx936 Perpendicular
Ebx318 Perpendicular
120
80
40
0 0 10 20 30 40 50 60 70 80
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P800
500
S800-02
T800
Shear Force (N)
400
P800 Predicted
300
S800-02 Predicted
T800 Predicted
200
100
0 0 10 20 30 40 50 60 70 80
woven fabric
200
Ebx318 Parallel
160
Ebx318 Perpendicular
120
80
40
0 0 10 20 30 40 50 60 70 80
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Tw/2
Fabric ID
P150 T800 S800-02 P800 S800-01 Ebx318 Ebx936
Style
Plain weave 2:2 Twill weave 4 Harness Satin Plain weave 4 harness Satin Pillar NCF Tricot 1&1
Ply Angles
0/90 0/90 0/90 0/90 0/90 +/-45 +/-45
cos li =
Tw T Tow s
Width (mm)
1.22 4.40 2.80 3.09 0.62 0.47 0.70
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10
0 0 10 20 30 40 50 60 70 80
Shear Angle
(o)
10
0 0 10 20 30 40 50 60 70 80
Shear Angle
(o)
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Compression Tension
Test 1 Test 2 Test 3 Test 4
5000
Tension
4000
3000
2000
1000
0 0 10 20 30 40 50
Compression
60 70 80
Sample misalignment can lead to: Tensile and/or compressive forces in tows Premature buckling of the sample
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Issues:
What materials properties are of interest? What properties and tests are required:
For formability assessment? For simulation?
How repeatable are test methods? Can we propose a series of standard tests?