Modelling compaction-induced defects in over moulding of thermoplastic composites
Modelling compaction-induced defects in over moulding of thermoplastic composites
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%.
Homogenisation, Overmoulding, Resin Flow
638-645
Association of American Publishers
Koptelov, Anatoly
af210438-5b27-41b3-bee0-8cb83a27217f
Wu, Xun
1e74bd51-8916-49ea-883b-371108be7ea5
Darby, Will
91aa91e5-2cca-4383-9549-c0f9201ff8bd
Parsons, Andrew
af9b2bcf-c01e-42fb-a727-9d433b55bdbc
Thomsen, Ole T.
f3e60b22-a09f-4d58-90da-d58e37d68047
Hallett, Stephen R.
ad7e5874-ad6e-4f61-9a10-1f7f98e25efd
Harper, Lee T.
52fcf388-01e5-43d8-a0f2-23d14015b465
Belnoue, Jonathan P.-H.
e4bd48b6-7d3f-495b-a9fb-c7c0208986ab
5 July 2025
Koptelov, Anatoly
af210438-5b27-41b3-bee0-8cb83a27217f
Wu, Xun
1e74bd51-8916-49ea-883b-371108be7ea5
Darby, Will
91aa91e5-2cca-4383-9549-c0f9201ff8bd
Parsons, Andrew
af9b2bcf-c01e-42fb-a727-9d433b55bdbc
Thomsen, Ole T.
f3e60b22-a09f-4d58-90da-d58e37d68047
Hallett, Stephen R.
ad7e5874-ad6e-4f61-9a10-1f7f98e25efd
Harper, Lee T.
52fcf388-01e5-43d8-a0f2-23d14015b465
Belnoue, Jonathan P.-H.
e4bd48b6-7d3f-495b-a9fb-c7c0208986ab
Koptelov, Anatoly, Wu, Xun, Darby, Will, Parsons, Andrew, Thomsen, Ole T., Hallett, Stephen R., Harper, Lee T. and Belnoue, Jonathan P.-H.
(2025)
Modelling compaction-induced defects in over moulding of thermoplastic composites.
Carlone, Pierpaolo, Filice, Luigino and Umbrello, Domenico
(eds.)
In 28th International ESAFORM Conference on Material Forming, ESAFORM 2025.
vol. 54,
Association of American Publishers.
.
(doi:10.21741/9781644903599-69).
Record type:
Conference or Workshop Item
(Paper)
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%.
Text
69
- Version of Record
More information
Published date: 5 July 2025
Venue - Dates:
28th International ESAFORM Conference on Material Forming, ESAFORM 2025, , Paestum, Italy, 2025-05-07 - 2025-05-09
Keywords:
Homogenisation, Overmoulding, Resin Flow
Identifiers
Local EPrints ID: 506853
URI: http://eprints.soton.ac.uk/id/eprint/506853
ISSN: 2474-3941
PURE UUID: 805de90d-c2f7-451a-b62a-d7a9da03f6c2
Catalogue record
Date deposited: 19 Nov 2025 17:34
Last modified: 20 Nov 2025 03:11
Export record
Altmetrics
Contributors
Author:
Anatoly Koptelov
Author:
Xun Wu
Author:
Will Darby
Author:
Andrew Parsons
Author:
Stephen R. Hallett
Author:
Lee T. Harper
Author:
Jonathan P.-H. Belnoue
Editor:
Pierpaolo Carlone
Editor:
Luigino Filice
Editor:
Domenico Umbrello
Download statistics
Downloads from ePrints over the past year. Other digital versions may also be available to download e.g. from the publisher's website.
View more statistics