Publications
back
Advances in virtual process chain and connection with on-line monitoring methods for first time right manufacturing of thermoset laminated composites
C. Brauner, A., Miene, M. Bruyneel, F. Pascon, A.S. Herrmann, NAFEMS World Congress, June 21-24, 2015, San Diego, US

The objective of this study is to present a coherent virtual process chain for a manufacturing process of composite structures which represents all physical effects leading to critical quality aspects such as process-induced deformations and stresses, injection and curing time as well as draping errors.
The virtual process chain consists of a kinematic draping approach, a sequential coupled thermochemical, thermomechanical analysis with cure dependent material models. In a transient approach the temperature and degree of cure is calculated based on the temperature boundary conditions of a process. Degree of cure is then used as state variable for a viscoelastic cure dependent material approach which represents the chemical and thermal contraction in a reliable way.
The virtual process models are as well parameterized and connected to Online Process Monitoring methods mainly an image analysis system which measures ply position, thickness and fiber orientation and a cure/resin flow measurements system based on resistance changes of the resin.
A comparison between the image analysis and FE-model is presented which enables to perform simulation of the “As-Built” configurations with the real fiber orientations, ply position and thickness/fiber volume content. Using this approach an analysis of warpage can be done after the fibre layup before the curing step and therefore process induced deformations as high risk factor based on asymmetrical layup can be determined. Especially for doubly curved parts the difference between virtual “As Planned” configurations and “As Built” configurations is often a large uncertainty which unnecessary extends the development phase. For cost efficient process design the combination of enhanced virtual models and online process monitoring is presented on a use case of a ship propeller which demonstrates the method on a doubly curved complex shaped geometry.

FP7 
The Seventh Framework Programme (FP7) bundles all research-related EU initiatives together under a common roof playing a crucial role in reaching the goals of growth, competitiveness and employment.

 

 

 

 

 

   

 

 

Project partners
 
DEUTSCHES ZENTRUM FUER LUFT-UND RAUMFAHRT E.V.  
AIRBORNE TECHNOLOGY CENTER B.V.  
BOMBARDIER AEROSPACE, BELFAST  
DASSAULT SYSTEMES SA  
FASERINSTITUT BREMEN EV  
HUTCHINSON SA  
LOOP TECHNOLOGY LIMITED  
STICHTING NATIONAAL LUCHT- EN RUIMTEVAARTLABORATORIUM  
POLYWORX BV  
SAMTECH SA  
SYNTHESITES INNOVATIVE TECHNOLOGIES LTD