An experimental study of mechanisms behind wrinkle development during forming of composite laminates

A general problem when forming quasi-isotropic, multilayer unidirectional (UD) prepreg over a double curved geometry is out-of-plane wrinkling. The presented study aims to show the existence of compression in the laminate in a recess area that is globally under tension during forming. Further it aims to investigate the influence of compression on the out-of-plane wrinkle development. An experimental study is performed with pre-stacked UD prepreg on a forming tool with varying cross section. Investigated parameters include lay-up sequence, prepreg ply thickness, inter-ply friction and prepreg ply impregnation. Experimental evaluation is performed on the out-of-plane defect height, type, location and number. Further, measurements are performed on the outer-ply deformation in the z-direction and inside the formed component using Micro CT. The study show that compression is to some degree always developed during forming of a recess area but that the lay-up sequence has a dominant effect on the wrinkling development.