Simulation of compression moulding process for long-fibre reinforced thermoset composites considering fibre bending

Abstract

Long-fibre-reinforced composite prepregs are introduced to achieve mass production of complex-shaped composite structures with appropriate mechanical properties. These composite prepregs consist of 50 mm long carbon fibres and rapid curing-type epoxy resin. To simulate the actual behaviour of composite prepregs during compression moulding, not only the general material flow and degree of cure but also the bending and orientation of the fibres were considered in finite element analysis. The fibre orientation and bending during forming process determined the local Young's modulus of the cured structure and made the structural analysis more realistic. The simulated warpage of the cured structure due to thermal residual stress caused by fibre orientation and bending was estimated and experimentally verified. © 2019 Elsevier Ltd