A simulation framework for predicting process-induced distortions for precise manufacturing of aerospace thermoset composites

Traiforos, Neoklis; Turner, T.A.; Runeberg, Patrik; Daoud, Fernaß; Chronopoulos, Dimitrios; Glock, Florian; Schuhmacher, G.; Hartung, Daniel

doi:10.1016/j.compstruct.2021.114465

Cited by 13 publications

(5 citation statements)

References 62 publications

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“…By comparing the predictions of the two material modes with the 3D scanned shape of the frame, it was found that the viscoelastic material model could predict more accurately the shape distortion of the part compared to the CHILE material model which was found to overestimate in magnitude the distortion of the frame [70,125]. Consequently, in the context of the OptiMACS project, viscoelastic material models are proposed to predict shape distortions of aerospace thermoset composite parts when the maximum prediction accuracy is sought.…”

Section: Manufacturing Distortionsmentioning

confidence: 99%

See 1 more Smart Citation

Recent progress, challenges and outlook for multidisciplinary structural optimization of aircraft and aerial vehicles

Corrado¹,

Ntourmas²,

Sferza³

et al. 2022

Progress in Aerospace Sciences

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Section: Manufacturing Distortionsmentioning

confidence: 99%

“…Figure 9: Diagram of the material modelling architecture (UMAT top used in the chemo-mechanical analysis, UMATHT bottom used in the thermal analysis.). Blue colour indicates variable calculation, purple access of memory, orange start/finish of the calculation process whereas the green box is employed only by the viscoelastic material model[70].…”

mentioning

confidence: 99%

Recent progress, challenges and outlook for multidisciplinary structural optimization of aircraft and aerial vehicles

Corrado¹,

Ntourmas²,

Sferza³

et al. 2022

Progress in Aerospace Sciences

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“…The shear modulus is considered almost zero below the gel point but rises rapidly above that point due to the formation of cross-linked structures. Johnston proposed an improved model and found that the curves trend in the same direction but the relationship between resin modulus and curing degree deviates at different temperatures, suggesting that the resin modulus is not only curing degree dependent but also temperature dependent, and the following modified CHILE (Tg) model as follow [9][10][11][12].…”

Section: Resultsmentioning

confidence: 99%

“…In order to make better use of the above-mentioned model and reflect the modulus change law of the curing process, and for better numerical simulation, the curing degree in the fine view structure with time is now expanded into a three-dimensional model, thus reflecting the modulus change law with time, as shown in Figure 8. Johnston proposed an improved model and found that the curves trend in the same direction but the relationship between resin modulus and curing degree deviates at different temperatures, suggesting that the resin modulus is not only curing degree dependent but also temperature dependent, and the following modified CHILE (Tg) model as follow [9][10][11][12].…”

Section: Resultsmentioning

confidence: 99%

Study of Critical Material Parameters for Curing Deformation of Aerospace Wing Composites before Numerical Simulation

2022

JBTS

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Because of the advantages of lightweight and high-strength integrated molding of composite materials at low cost, thus, large-scale carbon fiber composite structures are widely used in aerospace applications. However, the curing deformation of large-scale composite structures will produce a certain shape deviation, which cannot meet the needs of the installation. If forced assembly will form large installation stress, which will seriously jeopardize the mechanical properties and lifetime of the composite parts. Therefore, it is being studied to control the curing deformation of largescale composite structures, which is important to ensure the quality of the structure, reduce the cost and improve the service life of the structure. The traditional composite parts development model requires large-scale sample testing, uncontrollable manufacturing quality, low efficiency, and other problems. In particular, the curing and molding process involves the intersection of several disciplines such as thermal, chemical and mechanics, so it is increasingly important to study the curing deformation of large-scale composite structures to improve R&D efficiency, control quality, and reduce cost.

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“…Changing the mold shape for compensation does not require modification of the curing process or the lay-up, but entails the production of a new mold, as it is a trial-and-error approach. Another option is to utilize a numerical model introduced by Triforia et al [11]. Optimization of curing is another strategy to eliminate deformations.…”

Section: Introductionmentioning

confidence: 99%

Precision and Dimensional Stability of Bonded Joints of Carbon-Fibre-Reinforced Polymers Parts

Kupčák,

Zouhar,

Viliš

et al. 2023

Applied Sciences

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This article aims to investigate the accuracy and dimensional stability of bonded metal and CFRP (Carbon Fibre Reinforced Plastic) adherends. The motivation behind this study was to assess the suitability of CFRP for optical devices through the evaluation of precision bonding technology. A binocular was selected as a reference optical device. A technological sample was designed, with required total runout of key dimensions 0.05 mm. The sample underwent testing according to ISO 9022-1. The total runout was evaluated after production and environmental tests. Eight out of 15 samples were turned after gluing due to insufficient accuracy. None of the turned samples exceeded the total runout deviation of 0.01 mm, and the average value of the maximal deviation was 0.0041 mm. The noncalibrated samples performed significantly worse with the average value of the maximal deviation of 0.0164 mm. The measurements during the climatic tests showed that the largest deviation (on average 77.6% of the maximum achieved deviation) occurs at the first temperature loading. Subsequent temperature cycles caused lower deviations. The results highlight the significance of addressing deformations resulting from adhesive volume shrinkage-induced stress as a crucial factor in precision bonding technology.

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A simulation framework for predicting process-induced distortions for precise manufacturing of aerospace thermoset composites

Cited by 13 publications

References 62 publications

Recent progress, challenges and outlook for multidisciplinary structural optimization of aircraft and aerial vehicles

Recent progress, challenges and outlook for multidisciplinary structural optimization of aircraft and aerial vehicles

Study of Critical Material Parameters for Curing Deformation of Aerospace Wing Composites before Numerical Simulation

Precision and Dimensional Stability of Bonded Joints of Carbon-Fibre-Reinforced Polymers Parts

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