Embedded element approach for the design of modular forming
Dominic R. Palubiski, Janice M. Dulieu-Barton, Ian Hamerton, Dmitry S. Ivanov
Abstract. To address classical forming challenges, such as the susceptibility of highly compliant precursors to defects, we proposed the concept of modular forming, where formable zones are integrated into a fully cured blank of a composite structure. Reconfigurable vitrimer matrices are integrated in targeted regions that include embossed areas to accommodate generation of excess material during forming. Consequently, the structural blanks can be manufactured nearly flat and later assembled, thereby minimizing defect risks from infusion and localized ply deposition and, potentially, giving other benefits such as enabling cost-effective shipping. The effectiveness of this forming process depends on precise control of processing parameters and embossment geometry, hence computationally efficient modelling tools are required to optimise the process. To address this requirement, we employ an embedded element approach mostly used in structural multi-scale problems. The mesh of viscous host matrix (epoxy or vitrimer) is created independently of the mesh of discrete elastic plies. The coupling of these volumes prevents relative motion of plies in fully cured regions while permitting relative motion in embossed vitrimer zones – both reflecting physical behaviour. The deformations obtained from the model agree well with those from experiments, demonstrating the effectiveness and computational efficiency of the new modelling approach.
Keywords
Modular Forming, Multi-Matrix Systems, Embedded Finite Element Analysis
Published online 5/7/2025, 8 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Dominic R. Palubiski, Janice M. Dulieu-Barton, Ian Hamerton, Dmitry S. Ivanov, Embedded element approach for the design of modular forming, Materials Research Proceedings, Vol. 54, pp 536-543, 2025
DOI: https://doi.org/10.21741/9781644903599-58
The article was published as article 58 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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