PSI - Issue 66

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2025) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2025) 000–000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 66 (2024) 229–246

8 th International Conference on Crack Paths th International Conference on Crack Paths

A Comprehensive Review of Forming Methods for Composite Materials and Cracking Mohammad Jameel Ziedan 1 , AbdulKareem F. Hassan 2 , Najim A. Saad 3 , A.M. Al-Mukhtar 4, * 1 Department of Mechanical Engineering, College of Engineering, University of Basrah, Basrah, Iraq 2 College of Engineering, University of Almaaqal, Basrah, Iraq 1 , AbdulKareem F. Hassan 2 , Najim A. Saad 3 , A.M. Al-Mukhtar 4, * 1 Department of Mechanical Engineering, College of Engineering, University of Basrah, Basrah, Iraq 2 College of Engineering, University of Almaaqal, Basrah, Iraq

3 Faculty of Materials Engineering, Babylon University, Babylon Iraq 4 Institute of Structural Mechanics, Bauhaus-Universität Weimar, Germany 4 Al-Hussain University College, Iraq *Corresponding author: almukhtar@structuralintegrity.eu 3 Faculty of Materials Engineering, Babylon University, Babylon Iraq 4 Institute of Structural Mechanics, Bauhaus-Universität Weimar, Germany 4 Al-Hussain University College, Iraq *Corresponding author: almukhtar@structuralintegrity.eu

Abstract This review examines three primary forming techniques for composite materials: single-point incremental forming (SPIF), vacuum forming, and compression molding. SPIF involves applying localized pressure to thermoplastic sheets, enabling the formation of complex geometrical shapes. Vacuum forming uses vacuum pressure to mold heated sheets over forms, making it well-suited for large-scale production of simpler components. Compression molding, including techniques like Sheet Molding Compound (SMC) and Injection Molding, entails compressing heated composite materials in molds under high pressure to produce strong, durable parts. The discussion of the SPIF method will cover process parameters and optimization, SPIF of hole flanges, workpiece geometry, software tools, biocompatible polymers, and heating techniques. Additionally, the review will explore different formation types in vacuum forming and compression molding. Understanding these methods is crucial for various industries utilizing composite materials, particularly with regard to their cracking behavior. These techniques offer flexibility, efficiency, and precision in producing composite components with diverse geometries and properties, addressing contemporary engineering and design challenges. © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers Abstract This review examines three primary forming techniques for composite materials: single-point incremental forming (SPIF), vacuum forming, and compression molding. SPIF involves applying localized pressure to thermoplastic sheets, enabling the formation of complex geometrical shapes. Vacuum forming uses vacuum pressure to mold heated sheets over forms, making it well-suited for large-scale production of simpler components. Compression molding, including techniques like Sheet Molding Compound (SMC) and Injection Molding, entails compressing heated composite materials in molds under high pressure to produce strong, durable parts. The discussion of the SPIF method will cover process parameters and optimization, SPIF of hole flanges, workpiece geometry, software tools, biocompatible polymers, and heating techniques. Additionally, the review will explore different formation types in vacuum forming and compression molding. Understanding these methods is crucial for various industries utilizing composite materials, particularly with regard to their cracking behavior. These techniques offer flexibility, efficiency, and precision in producing composite components with diverse geometries and properties, addressing contemporary engineering and design challenges. © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers Keywords: Composite materials; Compression molding; Thermoforming; Thermoplastic; Single point incremental forming; Vacuum thermoforming. Keywords: Composite materials; Compression molding; Thermoforming; Thermoplastic; Single point incremental forming; Vacuum thermoforming. 1. Introduction Composite materials have been a subject of extensive research and development across various fields for several decades. Composite materials are engineered materials made from two or more constituent materials with different 1. Introduction Composite materials have been a subject of extensive research and development across various fields for several decades. Composite materials are engineered materials made from two or more constituent materials with different

* Corresponding author.. E-mail address: almukhtar@structuralintegrity.eu * Corresponding author.. E-mail address: almukhtar@structuralintegrity.eu

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers 10.1016/j.prostr.2024.11.074 2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the IGF chairpersons 2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. Peer-review under responsibility of the IGF chairpersons