Predicting consolidation-induced wrinkles and their effects on composites structural performance

Abstract

The majority of high-performance composite parts are nowadays designed using advanced numerical simulations that are able to accurately predict a part’s strength and deformation, providing that the internal ply architecture and exact fibre orientation are known with sufficient accuracy. However, most parts have some deviation of the fibre orientation from the ‘as-designed’ geometry, leading to the simulation overestimating the component’s strength. Up until recently, the advancement of the process simulation tools has not been sufficient to allow knowledge of this fibre deviation before any part has been manufactured, thus leading to overly conservative designs and costly experimental optimisation of the manufacturing process to reduce fibre path defects. This results in additional cost, waste of material and increased fuel consumption (due to the unnecessary weight of the components). This paper shows how state-of-the-art composite manufacturing simulations of the autoclave consolidation process can predict and help to mitigate against out-of-plane wrinkle formation in components made from toughened UD prepregs and thus raise confidence in failure analyses predictions. The industry relevant case of a stepped laminate is used as an example. Model predictions for the internal ply geometries are quantitatively compared to micrograph images of real samples. It is then shown how the input of the simulated ply architecture helps improving the accuracy of the failure simulations.

On the physical relevance of power law-based equations to describe the compaction behaviour of resin infused fibrous materials

“…is an extremely complex task. This, partly, explains why virtual process chains for composites have only recently started to appear in academia for the forming, followed by infusion of dry textiles [3] , prepreg technology [4] and also sheet moulding compound [5] . Because each of the processes described above involve fundamentally different physics, the tools to predict their outcome have, historically, been developed in isolation.…”

Lab-based in-situ micro-CT observation of gaps in prepreg laminates during consolidation and cure

“…The experiments were modelled using the composite manufacturing simulation tools developed by Belnoue et al [8,9,[37][38][39]. The model follows a hyper-viscoelastic formulation for anisotropic materials to account for the very soft nature of prepreg in the transverse direction, and its much stiffer behaviour along the fibre direction [8].…”

Hypo-viscoelastic modelling of in-plane shear in UD thermoset prepregs

“…As defects can be responsible for as much as 36% knockdown of the part mechanical performances [5,6], they should be avoided when possible.…”