Modelling of Composite Fabric Processing

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The overall goal is to provide simulation and design tools which will enable industry to design and manufacture composite components from textile preforms more efficiently. The project will focus on double-diaphragm forming of dry non-crimp fabrics (NCFs). Modelling of multi-layer forming will be developed to include ply-to-tool, ply-to-diaphragm and ply-to-ply friction. An empirical user-defined friction law will be developed within Abaqus finite element (FE) software to represent this behaviour. Experiments using double-diaphragm forming will validate the model. An optimisation design methodology based on machine learning will be developed to provide rapid prediction of the location of wrinkles and defects when forming large and complex shapes. This will be used to identify changes in geometric design or process conditions, which can deliver acceptable level of defects across the chosen demonstrator parts.