Simulation of Thermoplastic Composite Forming in Aerospace Application

Digital manufacturing techniques can simulate complex assembly sequences using 'as designed' part forms and their utility has been proven across the automotive and aerospace industries. However, the reality of working with composite components is that geometric variability arising from part forming or processing conditions, can cause problems during assembly as the 'as manufactured' form differs from the geometry used for any process capability definition or simulated build validation. Composites possess attractive properties such as improved structural performance and lower product weight. For thermoplastic based composites improved recyclability is another important factor as sustainability is a key requirement for transport systems of the future. This book introduces predictive methods and technologies for manufacturing practices based on carbon fibre reinforced thermoplastic materials. Equipped with the prediction and simulation technologies developed in this work, composite part design, manufacturability and build validation can now be included in the design process from the earliest conceptual stage where up to 80% of final product cost is determined.