Modelling compaction-induced defects in overmoulding of thermoplastic composites

Anatoly Koptelov; Xun Wu; Will T W Darby; Andrew Parsons; Ole Thomsen; Stephen R Hallett; Lee Harper; Jonathan P Belnoue

doi:10.21741/9781644903599-69

Modelling compaction-induced defects in overmoulding of thermoplastic composites

Anatoly Koptelov^*, Xun Wu, Will T W Darby, Andrew Parsons, Ole Thomsen, Stephen R Hallett, Lee Harper, Jonathan P Belnoue

^*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceeding › Conference Contribution (Conference Proceeding)

1 Citation (Scopus)

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%.

Original language	English
Title of host publication	28th International ESAFORM Conference on Material Forming, ESAFORM 2025
Editors	Pierpaolo Carlone, Luigino Filice, Domenico Umbrello
Publisher	Materials Research Forum LLC
Pages	638-645
Number of pages	8
Volume	54
ISBN (Print)	978-1-64490-359-9
DOIs	https://doi.org/10.21741/9781644903599-69
Publication status	Published - 7 May 2025
Event	The 28th International ESAFORM Conference on Material Forming - Paestum, Italy Duration: 7 May 2025 → 9 May 2025 https://www.esaform2025.it/

Publication series

Name	Materials Research Proceedings
Volume	54
ISSN (Print)	2474-3941
ISSN (Electronic)	2474-395X

Conference

Conference	The 28th International ESAFORM Conference on Material Forming
Abbreviated title	ESAFORM 2025
Country/Territory	Italy
City	Paestum
Period	7/05/25 → 9/05/25
Internet address	https://www.esaform2025.it/

Bibliographical note

Publisher Copyright:
© 2025, Association of American Publishers. All rights reserved.

Keywords

Overmoulding
Resin Flow
Homogenisation

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Koptelov, A., Wu, X., Darby, W. T. W., Parsons, A., Thomsen, O., Hallett, S. R., Harper, L., & Belnoue, J. P. (2025). Modelling compaction-induced defects in overmoulding of thermoplastic composites. In P. Carlone, L. Filice, & D. Umbrello (Eds.), 28th International ESAFORM Conference on Material Forming, ESAFORM 2025 (Vol. 54, pp. 638-645). (Materials Research Proceedings; Vol. 54). Materials Research Forum LLC. https://doi.org/10.21741/9781644903599-69

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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%.",

keywords = "Overmoulding, Resin Flow, Homogenisation",

author = "Anatoly Koptelov and Xun Wu and Darby, {Will T W} and Andrew Parsons and Ole Thomsen and Hallett, {Stephen R} and Lee Harper and Belnoue, {Jonathan P}",

note = "Publisher Copyright: {\textcopyright} 2025, Association of American Publishers. All rights reserved.; The 28th International ESAFORM Conference on Material Forming, ESAFORM 2025 ; Conference date: 07-05-2025 Through 09-05-2025",

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doi = "10.21741/9781644903599-69",

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Koptelov, A, Wu, X, Darby, WTW, Parsons, A, Thomsen, O , Hallett, SR, Harper, L & Belnoue, JP 2025, Modelling compaction-induced defects in overmoulding of thermoplastic composites. in P Carlone, L Filice & D Umbrello (eds), 28th International ESAFORM Conference on Material Forming, ESAFORM 2025. vol. 54, Materials Research Proceedings, vol. 54, Materials Research Forum LLC, pp. 638-645, The 28th International ESAFORM Conference on Material Forming, Paestum, Italy, 7/05/25. https://doi.org/10.21741/9781644903599-69

Modelling compaction-induced defects in overmoulding of thermoplastic composites. / Koptelov, Anatoly; Wu, Xun; Darby, Will T W et al.
28th International ESAFORM Conference on Material Forming, ESAFORM 2025. ed. / Pierpaolo Carlone; Luigino Filice; Domenico Umbrello. Vol. 54 Materials Research Forum LLC, 2025. p. 638-645 (Materials Research Proceedings; Vol. 54).

Research output: Chapter in Book/Report/Conference proceeding › Conference Contribution (Conference Proceeding)

TY - GEN

T1 - Modelling compaction-induced defects in overmoulding of thermoplastic composites

AU - Koptelov, Anatoly

AU - Wu, Xun

AU - Darby, Will T W

AU - Parsons, Andrew

AU - Thomsen, Ole

AU - Hallett, Stephen R

AU - Harper, Lee

AU - Belnoue, Jonathan P

PY - 2025/5/7

Y1 - 2025/5/7

N2 - 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%.

AB - 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%.

KW - Overmoulding

KW - Resin Flow

KW - Homogenisation

U2 - 10.21741/9781644903599-69

DO - 10.21741/9781644903599-69

M3 - Conference Contribution (Conference Proceeding)

SN - 978-1-64490-359-9

VL - 54

T3 - Materials Research Proceedings

SP - 638

EP - 645

BT - 28th International ESAFORM Conference on Material Forming, ESAFORM 2025

A2 - Carlone, Pierpaolo

A2 - Filice, Luigino

A2 - Umbrello, Domenico

PB - Materials Research Forum LLC

T2 - The 28th International ESAFORM Conference on Material Forming

Y2 - 7 May 2025 through 9 May 2025

ER -

Koptelov A, Wu X, Darby WTW, Parsons A, Thomsen O , Hallett SR et al. Modelling compaction-induced defects in overmoulding of thermoplastic composites. In Carlone P, Filice L, Umbrello D, editors, 28th International ESAFORM Conference on Material Forming, ESAFORM 2025. Vol. 54. Materials Research Forum LLC. 2025. p. 638-645. (Materials Research Proceedings). doi: 10.21741/9781644903599-69

Modelling compaction-induced defects in overmoulding of thermoplastic composites

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