Development of Finite Element Analysis Models for Reused Composite Oriented Strand Boards using SIMULIA ABAQUS

There is growing interest for the reused composite oriented strand board (COSB) for stiffness-critical and contoured applications. COSBs are made of rectangular shape prepreg strands that are randomly oriented within the structure. Development of this product form could markedly reduce the scrap generated during aerospace manufacturing processes. COSBs retain high modulus and drapability during processing and manufacturing. However, before any material can be deployed in industrial applications, the mechanical properties must be well understood so that proper design analysis can be performed. COSB has complex structure due to the randomly oriented prepreg strands, and this makes it difficult to model the stiffness using conventional methods. In general, a purely experimental hit and trail approach is used to design components out of such material.   In this project, a finite element based modelling approach to predict the stiffness of COSB is presented. A number of 2D and 3D complicated and realistic finite element models are developed in SIMULIA ABAQUS using different meshing and contact techniques including orphan meshing, embedded elements, tie constraints and cohesive surface and cohesive elements. The FEA model predictions are validated with experimentally determined stiffness and damage mechanisms of COSB samples manufactured using out of Autoclave (OoA) heated tool compression molding.   This research project was conducted and presented by M.C. Gill Composites Center at the University of Southern California and the IMDEA Materials Institute at Madrid Spain, and funded by NSF (National Science Foundation) G8 Initiative "Sustainable Manufacturing of Composite Materials" (Award # CMMI-1229011), and Airbus Institute for Engineering Research (AIER) program. The financial support from the Communidad de Madrid through the program DIMMAT (S2013/MIT-2775) is also gratefully acknowledged. Authors appreciate Prof. Stephen Tsai for his warm discussion and helpful suggestions.   High resolution video of the submission is available upon request.