Modelling compaction-induced defects in overmoulding of thermoplastic composites
Anatoly Koptelov, Xun Wu, Will Darby, Andrew Parsons, Ole T. Thomsen, Stephen R. Hallett, Lee T. Harper, Jonathan P.-H. Belnoue
Abstract. This study introduces a computationally efficient numerical tool for the design and manufacturing of thermoplastic overmoulded parts. The tool is set to predict compaction-induced wrinkles in overmoulded continuous fibre organosheets. Using a homogenisation approach, whereby the constitutive behaviour of each organosheet is described by the DefGen Protocol material model, allows to significantly reduce the required computational time in comparison with traditional ply-by-ply methods. Experimental characterisation of the material was performed under various processing conditions to extract model parameters, and results validation was conducted for small coupon tests and full-size industrial panels. The results showed high accuracy in predicting wrinkle geometry, with errors below 5%.
Keywords
Overmoulding, Resin Flow, Homogenisation
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: Anatoly Koptelov, Xun Wu, Will Darby, Andrew Parsons, Ole T. Thomsen, Stephen R. Hallett, Lee T. Harper, Jonathan P.-H. Belnoue, Modelling compaction-induced defects in overmoulding of thermoplastic composites, Materials Research Proceedings, Vol. 54, pp 638-645, 2025
DOI: https://doi.org/10.21741/9781644903599-69
The article was published as article 69 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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