On the modeling of separation foils in thermoforming simulations

Alexane Margossian, Sylvain Bel, Roland Hinterhölzl

Research output: Chapter in Book/Report/Conference proceedingsConference contributionpeer-review


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.

Original languageEnglish
Title of host publicationESAFORM 2016
Subtitle of host publicationProceedings of the 19th International ESAFORM Conference on Material Forming
EditorsElias Cueto, Francisco Chinesta, Emmanuelle Abisset-Chavanne
PublisherAmerican Institute of Physics Inc.
ISBN (Electronic)9780735414273
Publication statusPublished - 19 Oct 2016
Externally publishedYes
Event19th International ESAFORM Conference on Material Forming, ESAFORM 2016 - Nantes, France
Duration: 27 Apr 201629 Apr 2016

Publication series

NameAIP Conference Proceedings
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616


Conference19th International ESAFORM Conference on Material Forming, ESAFORM 2016

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