Towards a Digital Twin for High-Quality Curing of Multiple Composite Parts in Autoclave

Abstract

Autoclave processes require a balance between the throughput and quality of the cured composite parts. The curing process is a major factor that influences the quality as well as the manufacturing time, which in turn is governed by the thermal distribution of the composite part. Developing a digital twin for composite curing in an autoclave is essential to optimize the autoclave process, which involves simultaneously curing multiple parts and improving the thermal homogeneity to obtain high-quality parts. A physics-based digital twin is created to mirror the physical composite curing process in the virtual domain. The digital twin includes a thermal CFD model, a thermo-chemo-mechanical module, and an efficient and accurate block coupling between these two modules. The customized Abaqus driven by local and spatial variation of the turbulence-induced heat transfer coefficient imposed through one-way coupling determines the thermo-mechanical response in composite parts. The accuracy of the one-way coupling strategy is demonstrated first using a benchmark problem followed by the capability demonstration with a single-part L-beam assembly. The benefits of using the digital twin tool are illustrated via the optimal placement of multiple parts in an autoclave to balance the throughput and quality.