Finite element analysis and optimization of process parameters during stamp forming of composite materials

In the manufacture of parts for high performance structures using composite materials, the quality and robustness of the parts is of utmost importance. The quality of the produced parts depends largely on the process parameters and manufacturing methodologies. This study presents the use of a temperature dependant orthotropic material for a coupled structural-thermal analysis of the stamp forming process. The study investigated the effects of process parameters such as pre-heat temperature, blank holder force and process time on the formability of composite materials. Temperature was found to be the dominant factor governing the formability of the composite material while higher blank holder forces were deemed to be important for achieving high quality of the parts manufactured. Finally, an optimum set of parameters was used to compare the simulations with experimental results using an optical strain measurement system.