Double diaphragm forming simulation for net-shape component using multi-layered biaxial non-crimp fabrics

Compared to autoclave-cured prepreg, liquid composite moulding (LCM) is a cost-effective alternative produce advanced composites, thanks the less-expensive intermediate materials, lower capital investment and shorter cycle time. A separate preforming step typically required within process chain convert 2D fabric blanks into complex 3D geometries before moulding. Numerical models are therefore important ensure near net-shape preforms during design phase, in order minimise material wastage related preforming. In this study, microscale finite element (FE) model was employed assist determining ply shape of multi-ply biaxial non-crimp fabrics (NCF) achieve made by double diaphragm forming (DDF) using spar-like geometry. The deformation NCF predicted simulations considering in-plane stiffness NCF. location wrinkles indicated simulation membrane elements. By continuously removing redundant making contact with machine bed tool surface, were achieved for target geometry single multiple plies respectively. original shape, number reduced case due reduction bridging force induced pairing between fabric-diaphragm assembly bed.