Aerospace carbon fibre-reinforced components are cured under high pressure (7 bar) and temperature in an autoclave. As in an industrial environment, the loading of an autoclave usually changes from cycle to cycle causing different thermal masses and airflow pattern which leads to an inhomogeneous temperature distribution inside the carbon fiber-reinforced plastic part. Finally, the overall process can be delayed and the part quality can be compromised. In this paper, the heat transfer in a small laboratory autoclave has been investigated using calorimeter measurements and a fluid dynamic model. A complex turbulent flow pattern with locally varying heat transfer coefficient has been observed. Especially, the pressure and the inlet fluid velocity have been identified as sensitive process parameters. Further finite element simulations with adjusted boundary conditions provide accurate results of the curing process inside of the components for selective process control. The heat transfer coefficient has been found to be almost stationary during the observed constant pressure autoclave process allowing a separated investigation of the heat transfer coefficient and the curing of the components. The presented method promises therefore a detailed observation of the autoclave process with reduced computational effort.
Autoclave processing is the main technology used in the manufacturing of structural aerospace composite parts. To optimize the autoclave process, the thermal behavior of the part and mold can be investigated through simulations. Computational fluid dynamics (CFD) provide a significant contribution to studies on heat transfer and airflow patterns, which are key points in an optimization applied to achieve a homogeneous temperature distribution inside composite parts. The solution is produced by solving the 3 D unsteady Navier–Stokes equations. This paper describes a systematic numerical study using the CFD approach to significantly improve the modeling efficiency of the heat transfer coefficient (HTC) inside an autoclave and maintain a high level of accuracy. Considering the modeling cost, calculation time, and accuracy of the results, a reasonable hybrid mesh is used based on a mesh independency study. The level of grid independence is examined using the general Richardson extrapolation method. In addition, a more robust autoclave model is presented, which is unaffected by the inlet turbulence. Further, the inlet fluid velocity and turbulence models have been identified as sensitive influencing factors. In this study, the Spalart–Allmaras turbulence model shows the best performance compared with the standard [Formula: see text] and [Formula: see text] SST models. Finally, the results are validated with the experimental data. The mean error of the simulated temperatures in the calorimeter for the front, middle and rear positions are [Formula: see text]C, [Formula: see text]C, and [Formula: see text]C, indicating a good agreement with the experiments. This paper provides guidelines on the use of a CFD simulation to predict the heat transfer during the autoclave curing process with high accuracy and reduced numerical effort.
This study contributes to the understanding of the mechanism behind process-induced distortions and stresses related to the Resin Transfer Moulding manufacturing process. The objective is to comprehend the phenomena and to identify related parameters. During the manufacturing process, engineering constants of the matrix are changing and are influenced by the existence of a large number of effects. A viscoelastic material model has been derived. This developed material model integrates a dependency of the time–temperature–polymerisation and fibre volume content on the relaxation behaviour of residual stresses in a transversally isotropic reinforced material. The model is validated using a test case on the coupon level and results / limitations are discussed.
Structural aerospace composite parts are commonly cured through autoclave processing. To optimize the autoclave process, manufacturing process simulations have been increasingly used to investigate the thermal behavior of the cure assembly. Performing such a simulation, computational fluid dynamics (CFD) coupled with finite element method (FEM) model can be used to deal with the conjugate heat transfer problem between the airflow and solid regions inside the autoclave. A transient CFD simulation requires intensive computing resources. To avoid a long computing time, a quasi-transient coupling approach is adopted to allow a significant acceleration of the simulation process. This approach has been validated for a simple geometry in a previous study. This paper provides an experimental and numerical study on heat transfer in a medium-sized autoclave for a more complicated loading condition and a composite structure, a curved shell with three stringers, that mocks the fuselage structure of an aircraft. Two lumped mass calorimeters are used for the measurement of the heat transfer coefficients (HTCs) during the predefined curing cycle. Owing to some uncertainty in the inlet flow velocity, a correction parameter and calibration method are proposed to reduce the numerical error. The simulation results are compared to the experimental results, which consist of thermal measurements and temperature distributions of the composite shell, to validate the simulation model. This study shows the capability and potential of the quasi-transient coupling approach for the modeling of heat transfer in autoclave processing with reduced computational cost and high correlation between the experimental and numerical results.
Within this paper, it is shown that the assumption of transversal isotropy usually applied to unidirectional layers is not valid, if interleaf layers are introduced to increase the impact performance of the material. An approach is suggested to consider the meso-structure of composite materials with interleaf layers in the calculation of the elastic properties, the thermal expansion coefficients, and the chemical shrinkage coefficients. The approach uses known rules of mixture in a first step, to determine the properties of the carbon fiber–reinforced polymer layer as well as those of the interleaf layer and combine them in a second step by new meso-scale rules of mixture. The approach is discussed using known material data and shows to provide plausible results. The effects of the material properties influenced by the meso-scale rules of mixture on the process induced distortions are then discussed exemplary considering the thermally induced spring-in. It is shown that the meso-structure has a considerable influence on the process-induced distortions and cannot be neglected in the prediction of it.
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