A multi-physics process model for simulating the manufacture of resin-infused composite aerostructures

Abstract

The increasing demand for large, complex and low-cost composite aerostructures has motivated advances in the simulation of liquid composite moulding techniques with textile reinforcement materials. This work outlines the development and validation of a multi-physics process model that better simulates infusion behaviour through a complex preform compared with traditional models used in industry that do not account for fabric deformation. By combining the results of a preform draping model with deformation-dependent permeability properties, the shape and local flow characteristics of a deformed textile reinforcement have been more realistically defined for infusion. Simulated shear deformation results were used to define the distributed permeability properties across the fabric domain of the infusion model. Full-scale vacuum infusion experiments were conducted for a complex double dome geometry using a plain weave carbon fibre material. The multi-physics process model showed significant improvement over basic models, since it is able to account for the change in flow behaviour that results from local fabric deformation.

Effects of post-infusion dwell on vacuum infusion of thermoset composites toughened by thermoplastic interlaminar veils

“…The isotropy of the polyamide veil was unknown prior to testing, and the radial test configuration permitted simultaneous measurement of the two principal permeability values of an anisotropic material. 36,37 A vacuum-driven constant injection pressure experimental setup (Figure 2) was used, as demonstrated by Pierce et al 38,39 A single-ply sample was placed between a bottom tool plate and an upper polycarbonate caul plate (measured cavity thickness of 1.50 AE 0.05 mm), while breather cloth surrounded the sample periphery to establish an even pressure gradient and to maintain cavity thickness. Instead of epoxy resin, olive oil (Kirkland Signature) was infused as a facsimile resin to allow permeability measurement at ambient temperature, as the viscosity of olive oil at room temperature (measured, 0.07 Pa Á s) was consistent with that of the pre-heated RTM6 resin (<0.10 Pa Á s).…”

Small-diameter optical fibre sensor embedment for ambient temperature cure monitoring and residual strain evaluation of CFRP composite laminates produced by vacuum-assisted resin infusion

“…Commercial aircraft industry has moved in the direction of polymer composite materials, replacing metallic materials, to produce lighter, less part-count and more complex structures, allowing to reduce fuel consumption and carbon dioxide emissions and ultimately decrease costs [1], [2]. Further cost savings may be achieved by composite manufacture through liquid composite moulding (LCM) techniques, replacing autoclave manufacturing [2].…”

“…Commercial aircraft industry has moved in the direction of polymer composite materials, replacing metallic materials, to produce lighter, less part-count and more complex structures, allowing to reduce fuel consumption and carbon dioxide emissions and ultimately decrease costs [1], [2]. Further cost savings may be achieved by composite manufacture through liquid composite moulding (LCM) techniques, replacing autoclave manufacturing [2]. Vacuum assisted resin infusion (VARI) is one of the LCM technologies [3] that has proved to be well-suited to produce advanced structural parts for aircraft and aerospace industries, as it allows the manufacturing of large components with good reproducibility, mechanical properties and having, simultaneously, high fibre and low void contents.…”

Wrinkling in engineering fabrics: a comparison between two different comprehensive modelling approaches

“…So far, through-thickness rigidity is ignored but could also be introduced in future work (e.g. [ 1 ]). We refer to the two approaches as ‘semi-discrete’ and ‘continuum’ models, reflecting their semi-discrete and continuum-based natures.…”