Modelling defect formation in textiles during the double diaphragm forming process

As the requirement for low cost, high volume production of composites increases, so does the requirement for modelling capability to help inform and optimise the composite manufacturing processes. In this paper a finite element approach is introduced to simulate the behaviour of a plain weave fabric during the double diaphragm forming process. Using a mutually constrained shell-membrane method to capture the characteristic behaviours of the textile, the approach is assessed in its ability to predict the severe deformations present within experimental trials. The model is validated against experimental results for different fibre orientations and for the simultaneous forming of multiple layers. The approach accurately predicts the severe wrinkles observed in the experiments and is used to help further understand the catalysts for defect formation in the double diaphragm forming process.