Abstract

The focus on the contour sensitive part mating boundary conditions development, using software in the fabric deformation during the hand layup and automation of press-forming process is important in the development of composite materials. During the real life layup production processes, the fabric directional changes produced wrinkles and voids in the part produced. This directional changes are not really feasible as predicted for real life production process by the Drape simulation, where the process can be stopped and fabric direction changed to avoid the wrinkles. In this study, the fabric was pulled and adjusted before it was finally cured during the hand layup to conform to the shape of the contour sensitive part, but during the press forming process the mould closure prevent this pulling. This is not accounted for in the simulation process of the part. Therefore, there is the need for further research into the analysis of these mating boundaries conditions in real life with the prospect of automation process. This changes in boundary conditions as the material been deformed assumes the shape of the mould constitutes major challenges for the contour sensitive part production processes. This still need further development for its effective application in the composite material development.

Key words: Mating boundary, Drape-simulation, press forming, real-life process.