| The thermostamping process has the potential for making composite parts at the same rate and cost as the currently used steel parts in automobiles. Composite parts have advantages over steel because the composites are typically lighter than steel parts and the composite properties can be tailored for specific applications. To optimize the manufacturing process, a design tool is required to link the manufacturing of the composite to its in-service mechanical-behavior performance requirements, such as directionally dependent stiffness and strength and energy management during a crash situation. The finite element method is a numerical method that has potential to be such a design tool. The applicability of the explicit solver within finite element modeling, specifically LS-DYNA, is the focus of this research. Explicit solvers are designed for high-speed impact scenarios, e.g. the stamping of sheet steel. The advantages of an explicit solver over an implicit solver are better contact algorithms, better convergence for highly nonlinear problems such as the thermostamping process, and easier implementation of user defined material subroutines. The LS-DYNA finite element models range in complexity from as simple as a unit cell in pure shear to as complex as a double dome stamping model with multiple layers. |
