On the modeling of separation foils in thermoforming simulations

Composite forming simulations consist in modelling the forming process of composite components to anticipate the occurrence of potential flaws such as out-of-plane wrinkles and fibre re-orientation. Forming methods often consist of automated processes in which flat composite blanks are forced to comply with tool geometries. Although Finite Element forming simulations require the modelling of all stakeholders (blankholder, tooling and composite blank), consumables such as separation films are often not considered. Used in thermoforming processes, these films are placed between tooling and composite to ease part removal after forming. These films are also used to decrease tool/ply friction and thus, enhance forming quality. This work presents thermoforming simulations of pre-impregnated carbon fibre thermoplastic blanks in which separation films are modelled in the same manner as composite layers, i.e. by a layer of shell elements. The mechanical properties of such films are also characterised at the same temperature as forming occurs. The proposed approach is finally compared to the actual modelling method, in which separation films are not modelled as such but in which their influence is only considered within the friction coefficient between tooling and blank.