Thermostamping Simulation of a Carbon Fiber-Reinforced PAEK Composite Stringer

Abstract

The results of thermostamping simulation of a composite stringer demonstrator made from a high temperature plastic (PAEK) reinforced with 5-Harness Satin (5HS) weave carbon fiber fabric are presented in this paper. The effects of four different gripping configurations (A, B, C and D) and four different laminate layups ([0f]4 cross-ply, [45f]4 angle-ply, [0f/45f]s and [45f/0f]s quasi-isotropic layups) on the quality of the formed part are computationally investigated using AniForm™ software. The gripping configuration A consists of 22 pieces of extension spring with stiffness of 0.17 N/mm and pretension of 5.50 N. The configuration B consists of 8 pieces of extension spring with stiffness of 0.51 N/mm and pretension of 16.25 N. The configuration C uses the same type of spring as used in the configuration B, only its quantity is more (12 pieces). The configuration D is similar to the configuration C but they are different in the spring arrangement. Our simulation results show that regardless of the gripping configuration the quasi-isotropic layups demonstrate the lowest laminate sag while the angle-ply layup demonstrates the highest shear angle and thickness. For the slip-path length, it strongly depends on the layup and gripping configuration. As conclusion, the optimal choices for the thermoformed composite stringer demonstrator are cross-ply layup with configuration C, angle-ply layup and [45f/0f]s quasi-isotropic layup with configuration D, and [0f/45f]s quasi-isotropic layup with configuration B.