An Integrated Modeling Approach for Composite Processing

Abstract

Advanced composite material manufacturing often comprises of preform preheating, non-isothermal resin flow and cure. In the multi-step process, a previous step normally dictates the initial conditions of its immediate subsequent step, with each step alone typically involving highly coupled multi-physics. The inter-step dependency and complex multi-physics coupling pose a challenge to modeling, which is essential for composite process optimization, and process-to-mechanical performance effect evaluation. This paper introduces an integrated predictive modeling approach for modeling the vacuum assisted resin transfer molding process including preheating, resin infusion and cure. Using this approach, models are developed for thick non-crimp fabric laminates, in which non-isothermal resin flow is found to be important. The part sizes are designed to be representative of typical engineering applications. Predictions of processing parameters such as temperature, flow-front, and cure exotherm are validated with experimental results. The proposed approach provides a practical route to new resin system development and composite process optimization to increase the rate of success for desired mold filling and structural integrity, with minimum residual stress from the exothermic resin cure process.