Modelling approach for anisotropic inter-ply slippage in finite element forming simulation of thermoplastic UD-tapes

Finite Element (FE) forming simulation offers the possibility of a detailed analysis of thermoforming processes by means of constitutive modelling of intra- and inter-ply deformation mechanisms, which makes manufacturing defects predictable. Inter-ply slippage is a deformation mechanism, which influences the forming behaviour and which is usually assumed to be isotropic in FE forming simulation so far. Thus, the relative (fibre) orientation between the slipping plies is neglected for modelling of frictional behaviour. Characterization results, however, reveal a dependency of frictional behaviour on the relative orientation of the slipping plies. In this work, an anisotropic model for inter-ply slippage is presented, which is based on an FE forming simulation approach implemented within several user subroutines of the commercially available FE solver Abaqus. This approach accounts for the relative orientation between the slipping plies for modelling frictional behaviour. For this purpose, relative orientation of the slipping plies is consecutively evaluated, since it changes during forming due to inter-ply slipping and intra-ply shearing. The presented approach is parametrized based on characterization results with and without relative orientation for a thermoplastic UD-tape (PA6-CF) and applied to forming simulation of a generic geometry. Forming simulation results reveal an influence of the consideration of relative fibre orientation on the simulation results. This influence, however, is small for the considered geometry.Finite Element (FE) forming simulation offers the possibility of a detailed analysis of thermoforming processes by means of constitutive modelling of intra- and inter-ply deformation mechanisms, which makes manufacturing defects predictable. Inter-ply slippage is a deformation mechanism, which influences the forming behaviour and which is usually assumed to be isotropic in FE forming simulation so far. Thus, the relative (fibre) orientation between the slipping plies is neglected for modelling of frictional behaviour. Characterization results, however, reveal a dependency of frictional behaviour on the relative orientation of the slipping plies. In this work, an anisotropic model for inter-ply slippage is presented, which is based on an FE forming simulation approach implemented within several user subroutines of the commercially available FE solver Abaqus. This approach accounts for the relative orientation between the slipping plies for modelling frictional behaviour. For this purpose, relative orientat...