A press forming benchmark to isolate deformation mechanisms for simulation validation

Abstract

Predictive simulations of the press forming process for thermoplastic composites are invaluable tools for designing tool geometry and determining processing parameters. Ensuring the reliability of these simulations requires thorough validation, which can be challenging due to the wide range of possible geometries and the time and costs associated with obtaining validation data. This study presents and interprets press forming results for thermoplastic composites, with a specific focus on their application to simulation model validation. Experiments were conducted by forming blanks made from two unidirectional fiber-reinforced thermoplastic composite materials over a dome-shaped geometry. By varying the blank width and layup, the deformations and wrinkling behavior were systematically influenced. It is demonstrated that a careful selection of the forming conditions enables targeted analysis and validation of individual deformation mechanisms, including in-plane shear, bending and interply friction. Finally, a structured strategy is proposed for using these experimental results to validate forming simulations, offering an approach to evaluate the used constitutive models.