Shuai Chen

Contact

• workRoom C31 Advanced Manufacturing Building
  Jubilee Campus
  Wollaton Road
  Nottingham
  NG8 1BB
  UK
• Shuai.Chen@nottingham.ac.uk

Biography

Dr Shuai Chen is a Senior Research Fellow in Composites Research Group. His current research focuses on design, analysis, and optimisation of composites forming process for Automotive & Aerospace sectors. He has specialised in the development of composites manufacturing processes and simulations, and is committed to supplying feasible solutions for high-quality and defect-free preforms by material/process optimisation based on finite element (FE) simulation.

Till 2020, Dr Chen has worked for 1 EPSRC Core Project, 3 EPSRC Feasibility Studies and 5 Innovate UK projects regarding advancements in composites manufacturing. He developed non-standard non-orthogonal constitutive models, built a set of matched-tool forming rigs and a novel diaphragm forming kit at the University of Nottingham. These have already been successfully adopted by UK automotive/aerospace OEMs. Dr Chen has also established a series of optimisation methodologies for different industrial applications. His research has made significant impact on the UK mechanical industry in terms of cost savings and processing time reduction.

Dr Shuai Chen was invited as a Session Chair of "Process modelling" for 21st International Conference on Composite Materials 2017. His research on composites manufacturing was exhibited in Paris with Hexcel at JEC-World 2018. He did give a presentation at the Advanced Engineering Show 2019. Also, he presented at the EPSRC Future Composites Manufacturing Research Hub (the "Hub") open days, international conferences (such as ICCM, ECCM, ICMAC, Composites@Manchester Workshop, etc.). Dr Chen was one of the funded researchers from the University of Nottingham on an Innovate UK project called CHASSIS, which has been awarded the Innovation in Design award at the Composites UK Industry Awards 2020.

Recently, Dr Shuai Chen has been granted two feasibility studies from the EPSRC Future Composites Manufacturing Research Hub, which are "Simulation of forming 3D curved sandwich panels" (Co-I) and "An innovative approach to manufacturing closed-section composite profiles" (PI), to initiate the worldwide growth of the concept on forming 3D fabric feedstock recognised as a step-changing area in composites manufacturing research. His research is to challenge the boundary of composites manufacturing by fully unlocking the modelling/optimisation capability for development of a next-generation technique, aiming at a significant breakthrough in manufacturing rate. Dr Chen is intended to finally make state-of-the-art composites widely affordable, benefiting full-scale industrial upgrading toward Industry 4.0.

Research Summary

(07/2020-present) EPSRC Future Composites Manufacturing Research Hub (EPSRC CIMComp) Core Project: Design simulation tools and process improvements for NCF preforming, specialised in developing… read more

Selected Publications

• CHEN, S., JOESBURY, A. M., YU, F., HARPER, L. T. and WARRIOR, N. A., 2022. Optimisation of intra-ply stitch removal for improved formability of biaxial non-crimp fabrics: Composites Part B: Engineering Composites Part B: Engineering. 229,
• CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2018. Optimisation of local in-plane constraining forces in double diaphragm forming: Composite Structures Composite Structures. 201, 570-581
• CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., ELSMORE, M.T., DE FOCATIIS, D.S.A., HARPER, L.T. and WARRIOR, N.A., 2017. Double diaphragm forming simulation for complex composite structures Composites Part A: Applied Science and Manufacturing. 95, 346–358
• CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2016. Defect formation during preforming of a bi-axial non-crimp fabric with a pillar stitch pattern Composites Part A: Applied Science and Manufacturing. 91, 156-167

• View all publications

Current Research

(07/2020-present) EPSRC Future Composites Manufacturing Research Hub (EPSRC CIMComp) Core Project: Design simulation tools and process improvements for NCF preforming, specialised in developing high-fidelity numerical tools for NCF forming simulation and process optimisation

(04/2020-present) Enhanced Characterisation and Simulation Methods for Thermoplastic Overmoulding, Innovate UK (#105799), specialised in modelling the material behaviour under different loading cases for thermoplastic overmoulding panels

Past Research

(04/2019-03/2020) EPSRC CIMComp: An innovative approach to manufacturing closed-section composite profiles, Principal Investigator, specialised in implementing experimental trials of the process to investigate the formability of closed-section composite profiles, to understand the defect modes and its mechanisms, and to identify main factors for process control (Industry partner: GMD)

(08/2018-03/2019) Composite Hybrid Automotive Suspension System Innovative Structures (CHASSIS), Innovate UK (#103362), specialised in simulating the creep behaviour of thermos-plastic composite components for automotive application. (Industry partner: Ford, NCC, AutoTech)

(02/2018-07/2018) EPSRC CIMComp: Simulation of forming 3D curved sandwich panels, Co-Investigator, specialised in developing a multi-scale FE model for sandwich panel forming to accelerate this step change in composite manufacturing (Industry partner: GMD)

(09/2016-02/2018) Thermoplastic Overmoulding for Structural Composite Automotive Application, Innovate UK (#102663), specialised in developing a thermoplastic material model to predict forming behaviour and defects (Industry partners: SG, JLR, AMRC, LMAT, Nifco, Engenuity)

(08/2016-07/2017) Affordable Composites for Lightweight Vehicles (ACLIV), Innovate UK (#132231), specialised in identifying defect mechanism for diaphragm forming process by simulation and conducting process optimisation to determine defect-free manufacturing solutions (Industry partners: Hexcel, Prodrive)

(09/2014-08/2016) Affordable Lightweighting through Pre-form Automation (ALPA), Innovate UK (#101879), specialised in establishing a non-orthogonal constitutive model for NCFs, developing Abaqus user-defined subroutines, experimental validation and forming kit design (Industry partners: McLaren, Hexcel, AMRC, MTC)

(05/2013-08/2014) EPSRC CIMComp Feasibility Study: Modelling forming of multi-ply preforms, specialised in simulation for producing complex 3D multi-ply preforms in a single stamping operation with inter-ply binders (Industry partners: McLaren, ESI)

• LAWRENCE, G. D., CHEN, S., WARRIOR, N. A. and HARPER, L. T., 2023. The influence of inter-ply friction during double-diaphragm forming of biaxial NCFs: Composites Part A: Applied Science and Manufacturing Composites Part A: Applied Science and Manufacturing. 167,
• YU, F., CHEN, X., CHEN, S. and HARPER, L.T., 2023. Numerical Study on the Formation of Defects During Double Diaphragm Forming Using a Biaxial Non-crimp Fabric In: roceedings of the 10th Chinese Society of Aeronautics and Astronautics Youth Forum.
• CHEN, S., HARPER, L.T. and CLIFFORD, M.J., 2023. Chapter 5 - Two-dimensional to three-dimensional dry fibre preforming. In: HARPER, L.T. and CLIFFORD, M.J., eds., Design and Manufacture of Structural Composites 1st edition. 101-123
• CHEN, S. and YU, F., 2023. 15 - Process simulation: Fabric forming. In: HARPER, L.T. and CLIFFORD, M.J., eds., Design and Manufacture of Structural Composites 1st edition. 373-400
• VIISAINEN, J.V., YU, F., CODOLINI, A., CHEN, S., HARPER, L.T. and SUTCLIFFE, M.P.F., 2023. Rapidly predicting the effect of tool geometry on the wrinkling of biaxial NCFs during composites manufacturing using a deep learning surrogate model Composites Part B: Engineering. 253, 110536
• GUO, K., CHEN, S., WEN, L. and XIAO, J., 2023. Prediction of dome thickness for composite pressure vessels from filament winding considering the effect of winding pattern Composite Structures. 306, 116580
• CHEN, S., JOESBURY, A. M., YU, F., HARPER, L. T. and WARRIOR, N. A., 2022. Optimisation of intra-ply stitch removal for improved formability of biaxial non-crimp fabrics: Composites Part B: Engineering Composites Part B: Engineering. 229,
• YU, F., CHEN, X. and CHEN, S., 2022. Double diaphragm forming simulation for net-shape component using multi-layered biaxial non-crimp fabrics Journal of Physics: Conference Series.
• YU, F., CHEN, S. and HARPER, L., 2021. Simulating the effect of fabric bending stiffness on the wrinkling behaviour of biaxial fabrics during preforming Composites Part A: Applied Science and Manufacturing. 143, 106308
• YU, F., CHEN, S., HARPER, L. T. and WARRIOR, N. A., 2021. Double diaphragm forming simulation using a global-to-local modelling strategy for detailed defect detection in large structures: Composites Part A: Applied Science and Manufacturing Composites Part A: Applied Science and Manufacturing. 147,
• YU, F., CHEN, S., HARPER, L. T. and WARRIOR, N. A., 2021. Investigation into the effects of inter-ply sliding during double diaphragm forming for multi-layered biaxial non-crimp fabrics: Composites Part A: Applied Science and Manufacturing Composites Part A: Applied Science and Manufacturing. 150,
• CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2020. Simulation of the forming process for curved composite sandwich panels International Journal of Material Forming. 13(6), 967-980
• BUSSETTA, P., GOMES, R., CHEN, S., MCGREGOR, O.P.L., HARPER, L.T., HARRISON, P. and CORREIA, C., 2020. Optimisation of hot-forming process through in-plane constraints: Numerical and experimental studies In: 18th European Conference on Composite Materials.
• YU, F., CHEN, S., VIISAINEN, J.V., SUTCLIFFE, M.P.F., HARPER, L.T. and WARRIOR, N.A., 2020. A macroscale finite element approach for simulating the bending behaviour of biaxial fabrics Composites Science and Technology. 191,
• CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2019. Finite element forming simulation of complex composite sandwich panels In: 22nd International Conference on Composite Materials.
• YU, F., CHEN, S., HARPER, L.T. and WARRIOR, N.A., 2019. A finite element forming model for bi-axial fabrics considering material bending stiffness In: 22nd International Conference on Composite Materials.
• CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2018. Optimisation of local in-plane constraining forces in double diaphragm forming: Composite Structures Composite Structures. 201, 570-581
• CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., ELSMORE, M.T., DE FOCATIIS, D.S.A., HARPER, L.T. and WARRIOR, N.A., 2017. Double diaphragm forming simulation for complex composite structures Composites Part A: Applied Science and Manufacturing. 95, 346–358
• MCGREGOR, O.P.L., CHEN, S., HARPER, L.T., ENDRUWEIT, A. and WARRIOR, N.A., 2017. Defect reduction in the double diaphragm forming process In: 21st International Conference on Composite Materials.
• CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2017. Optimisation of double diaphragm forming process through local adjustment of in-plane constraint In: 21st International Conference on Composite Materials.
• CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2016. Defect formation during preforming of a bi-axial non-crimp fabric with a pillar stitch pattern Composites Part A: Applied Science and Manufacturing. 91, 156-167
• CHEN, S., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2015. Inter-ply stitching optimisation of highly drapeable multi-ply preforms Composites Part A-Applied Science and Manufacturing. 71, 144-156
• CHEN, S., HARPER, L.T., ENDRUWEIT, A. and WARRIOR, N.A., 2015. Formability optimisation of fabric preforms by controlling material draw-in through in-plane constraints Composites Part A: Applied Science and Manufacturing. 76, 10-19
• MCGREGOR, O.P.L., CHEN, S., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2015. Defect characterisation and selective stitch removal in Non-Crimp Fabrics In: Sampe Europe Conference.
• CHEN, S., CHEN, S. and CHEN, S., 2015. Optimisation of forming process for highly drapeable fabrics In: 20th International Conference on Composite Materials.
• CHEN, S., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2014. Forming simulations of multi-layered woven preforms assembled with stitch yarns In: 16th European Conference on Composite Materials.