Composite forming simulations: From fundamental research to industrial application

This paper introduces two advances in finite element analysis of composite forming processes. One of the advances ensures the correctness of the simulations from the most basic principles of the finite element method. It concerns the recognition of, and a remedy for, a new type of numerical locking, namely intra-ply shear locking, which is specific to simulations of fibre reinforced composites. Here the intra-ply shear locking refers to a purely numerical problem, which is irrelevant from physical lockups of fabric structures. The other advance enables efficiency of forming simulations. It is related to the time step limitations in explicit solution method. A new type of scaling technology, namely selective E-scaling, is proposed to speed up simulations. The significances of these two advances are demonstrated by simulations of industrial-scale composite forming processes.