Experimental characterization and numerical modelling of bending behavior of carbon fiber unidirectional thermoset prepregs

To enhance the prediction accuracy of forming simulations of carbon fiber unidirectional (UD) thermoset prepregs, particularly the wrinkle predictions, bending behavior of UD prepregs in the forming process needs to be accurately characterized and modelled. In this paper, an improved bending test system was proposed to characterize the bending behavior of UD prepregs at different forming temperatures and loading rates. It is found that both the temperature and the loading rate have significant impact on the bending stiffness of UD prepregs. An obvious nonlinear bending behavior can be noted in the fiber direction. The loading rate sensitivity of bending stiffness in the fiber direction decreases with temperature increasing. To simulate the bending deformation, a superimposed membrane-shell element model was employed to achieve the decoupling of tensile-bending deformation. Membrane element simulated the in-plane tensile and in-plane shear deformations of UD prepregs, while shell element primarily accounted for the bending deformation. Fiber orientation dependent nonlinear bending stiffness was accounted in the model. Deformation simulations were conducted for vertical cantilever bending, horizontal cantilever bending, and compression wrinkling of UD prepregs. Good agreement is noted between simulation and experiment, demonstrating efficiency of the model and validity of measured bending stiffness.