Abstract
In this paper, we propose a new FE model of a carbon fiber reinforced thermoplastic (CFRTP) in order to capture the deformation during a thermoforming process because the thermoforming process of CFRTP has increased its presence in the automotive industry for its wide applicability to the mass production car. The proposed model can describe temperature dependent non-linear bending property of CFRTP by a set of elements which consists of two shell elements with membrane elements in between them. The membrane elements represent temperature dependent anisotropic in-plane behavior by calculating stress contributions of the textile reinforcement and thermoplastic in a parallel system. By applying Reuss model to the stress calculation of thermoplastic, the in-plane shear behavior which is the key deformation mode during forming can be accurately predicted. FE model is constructed based on the results of three point bending and bias-extension experiments which are conducted in the range of the process temperature. Thermoforming simulations are presented and compared to experimental results. Simulated outline and shear angle are in good agreement with experimental results. It will be shown by sensitivity study that the effect of the temperature plays an important role in deformation during a non-isothermal forming process.
