Simulation method for curing deformation of composite part considering tool-part interaction

doi:10.19936/j.cnki.2096-8000.20231028.002

Abstract

Abstract: For the assembly problems caused by the curing deformation of L-shaped composite structure, a simulation model of the curing deformation of composite considering the tool-part interaction was established. Firstly, the shear slip effect of the tool on the composite structure during curing process was characterized using the method of setting the friction coefficient with the maximum shear stress. Secondly, the effects of composite anisotropy, material thermal expansion and contraction, and matrix chemical shrinkage on the curing deformation were considered. Finally, the cure hardening instantaneously linear elastic model was used to realize the curing deformation simulation calculation under the premise of effectively improving the computational efficiency. On this basis, the validity of the simulation model was verified by designing experiments of curing deformation of L-shaped structures with different thicknesses and different lay-up sequences. The experimental and simulation analysis results were compared with a maximum error of -20.8% and an average error of -7.35%. The results show that for L-shaped structural parts prepared by aluminum molds, the tool-part interaction exacerbates the curing deformation situation of the structure, and the structural stiffness plays an important role in this deformation.

Key words: composite, curing deformation, finite element analysis, tool-part interaction, curing reaction

CLC Number:

TB332

YUAN Zhenyi, WEI Fangjian, KONG Lingfei, YANG Zhenchao, TONG Xinxing, LI Yan. Simulation method for curing deformation of composite part considering tool-part interaction[J]. COMPOSITES SCIENCE AND ENGINEERING, 2023, 0(10): 10-16.

References

[1] FAN S J, ZHANG J M, WANG B, et al. A deep learning method for fast predicting curing process-induced deformation of aeronautical composite structures[J]. Composites Science and Technology, 2023, 232: 109844.
[2] WANG B, FAN S J, CHEN J P, et al. A review on prediction and control of curing process-induced deformation of continuous fiber-reinforced thermosetting composite structures[J]. Composites Part A: Applied Science and Manufacturing, 2023, 165: 107321.
[3] SUN L S, LIU C, XU X W, et al. An integrated approach for rapidly and precisely predicting the spring-in of U-shaped composite parts with ply drop-offs[J]. Thin-Walled Structures, 2023, 184: 110473.
[4] 孙立帅, 刘闯, 李玉军, 等. 变厚度复合材料U型零件固化变形仿真预测与结构影响因素[J]. 复合材料学报, 2023, 40(1): 553-566.
[5] YUAN Z Y, WANG Y J, PENG X Q, et al. An analytical model on through-thickness stresses and warpage of composite laminates due to tool-part interaction[J]. Composites Part B: Engineering, 2016, 91: 408-413.
[6] MOBARAKIAN M, SAFARABADI M, FARAHANI M. Developing a thermomechanical and thermochemical model for investigating the cooling rate effects on the distortion of unsymmetrical viscoelastic polymeric composite laminates[J]. Polymer Testing, 2020, 87: 106503.
[7] SUN L L, WANG J H, NI A Q, et al. Modelling and experiment of process-induced distortions in un-symmetrical laminate plates[J]. Composite Structures, 2017, 182: 524-532.
[8] RADFORD D W, RENNICK T S. Separating sources of manufacturing distortion in laminated composites[J]. Journal of Reinforced Plastics and Composites, 2000, 19: 621-641.
[9] WISNOM M R, POTTER K D, ERSOY N. Shear-lag analysis of the effect of thickness on spring-in of curved composites[J]. Journal of Composite Materials, 2007, 49(14): 1311-1324.
[10] 王乾, 关志东, 王仁宇, 等. 结构参数对复合材料V型构件固化变形影响试验及解析分析[J]. 复合材料学报, 2017, 34(12): 2722-2733.
[11] DING A X, FANG S R, LI X, et al. Experimental and numerical investigation of tool-part interaction on the process-induced distortions in composite structures[J]. Composite Structures, 2022, 279: 114871.
[12] DING A X, WANG J H, NI A Q, et al. A new analytical solution for cure-induced spring-in of L-shaped composite parts[J]. Composites Science and Technology, 2019, 171: 1-12.
[13] TAKAGAKI K, MINAKUCHI S, TAKEDA N. Process-induced strain and distortion in curved composites. Part I: Development of fiber-optic strain monitoring technique and analytical methods[J]. Composites Part A: Applied Science and Manufacturing, 2017, 103: 236-251.
[14] BELLINI C, SORRENTINO L, POLINI W, et al. Spring-in analysis of CFRP thin laminates: Numerical and experimental results[J]. Composite Structures, 2017, 173: 17-24.
[15] FIORINA M, SEMAN A, BRUNO C, et al. Spring-in prediction for carbon/epoxy aerospace composite structure[J]. Composite Structures, 2017, 168: 739-745.
[16] REN M F, WANG Q, CONG J, et al. Study of one-dimensional cure simulation applicable conditions for thick laminates and its comparison with three-dimensional simulation[J]. Science and Engineering of Composite Materials, 2018, 25: 1197-1204.
[17] YUAN Z Y, KONG L F, GAO D J, et al. Multi-objective approach to optimize cure process for thick composite based on multi-field coupled model with RBF surrogate model[J]. Composite Communicationss, 2021, 24: 100671.
[18] ÇINAR K, ÖZTÜRK U E, ERSOY N, et al. Modelling manufacturing deformations in corner sections made of composite materials[J]. Journal of Composite Materials, 2014, 48(7): 799-813.
[19] BOGETTI T A, GILLESPIE J W. Two-dimensional cure simulation of thick thermosetting composites[J]. Journal of Composite Materials, 1991, 25: 239-273.
[20] HUI X Y, XU Y J, ZHANG W H. An integrated modeling of the curing process and transverse tensile damage of unidirectional CFRP composites[J]. Composite Structures, 2021, 263: 113681.
[21] YUAN Z Y, WANG Y J, YANG G G, et al. Evolution of curing residual stresses in composite using multi-scale method[J]. Composites Part B: Engineering, 2018, 155: 49-61.
[22] YOON K J, KIM J S. Induced distortion of carbon/epoxy curved laminates effect of thermal deformation and chemical shrinkage on the process [J]. Journal of Composite Materials, 2001, 35: 253-263.
[23] 高龙飞, 徐鹏, 王世杰, 等. 基于X850预浸料体系的工型长桁层压件固化变形仿真技术研究[J]. 复合材料科学与工程, 2020 (4): 60-64.
[24] WUCHER B, LANI F, PARDOEN T, et al. Tooling geometry optimization for compensation of cure-induced distortions of a curved carbon/epoxy C-spar[J]. Composites Part A: Applied Science and Manufacturing, 2014, 56: 27-35.
[25] WANG Q, LI T, YANG X F, et al. Prediction and compensation of process-induced distortions for L-shaped 3D woven composites[J]. Composites Part A: Applied Science and Manufacturing, 2021, 141: 106211.
[26] 岳波, 许英杰, 徐宁鑫, 等. 热压罐成型框架式模具结构拓扑优化设计[J]. 航空学报, 2022, 43(3): 541-553.
[27] VERMES B, CZIGANY T. Thermally induced mechanical work and warpage compensation of asymmetric laminates[J]. Composite Structures, 2022, 295: 115847.
[28] GAO Y, YE J, YUAN Z Y, et al. Optimization strategy for curing ultra-thick composite laminates based on multi-objective genetic algorithm[J]. Composites Communications, 2022, 31: 101115.
[29] STRUZZIERO G, NARDI D, SINKE J, et al. Cure-induced residual stresses for warpage reduction in thermoset laminates[J]. Journal of Composite Materials, 2020, 54: 3055-3065.
[30] 肖遥, 李东升, 吉康, 等. 大型复合材料航空件固化成型模具技术研究与应用进展[J]. 复合材料学报, 2022, 39(3): 907-925.
[31] YUAN Z Y, YANG G G, YANG Z C, et al. Process-induced deformation of L-shaped laminates analysis of tool-part interaction[J]. Mechanics of Composite Materials, 2021, 56(6): 789-804.
[32] ÇINAR K, ERSOY N. 3D finite element model for predicting manufacturing distortions of composite parts[J]. Journal of Composite Materials, 2016, 50(27): 3791-3807.
[33] 陈祥宝, 邢丽英, 周正刚. 树脂基复合材料制造过程温度变化模拟研究 [J]. 航空材料学报, 2009, 29(2): 61-65.
[34] LI X Y, WANG J H, LI S X, et al. Cure-induced temperature gradient in laminated composite plate: Numerical simulation and experimental measurement[J]. Composite Structures, 2020, 253: 112822.
[35] MEZEIX L, SEMAN A, NASI M N M, et al. Spring-back simulation of unidirectional carbon/epoxy flat laminate composite manufactured through autoclave process[J]. Composite Structures, 2015, 124: 196-205.
[36] BAPANAPALLI S K, SMITH L V. A linear finite element model to predict processing-induced distortion in FRP laminates[J]. Composites Part A: Applied Science and Manufacturing, 2005, 36(12): 1666-1674.
[37] KAUSHIK V, RAGHAVAN J. Experimental study of tool-part interaction during autoclave processing of thermoset polymer composite structures[J]. Composites Part A: Applied Science and Manufacturing, 2010, 41: 1210-1218.
[38] MOURE M M, OTERO F, GARCÍA-CASTILLO S, et al. Damage evolution in open-hole laminated composite plates subjected to in-plane loads[J]. Composite Structures, 2015, 133: 1048-1057.
[39] 岳广全. 整体化复合材料壁板结构固化变形模拟及控制方法研究[D]. 哈尔滨: 哈尔滨工业大学, 2010.
[40] TWIGG G, POURSARTIP A, FERNLUND G. Tool-part interaction in composites processing. Part I: Experimental investigation and analytical model[J]. Composites Part A: Applied Science and Manufacturing, 2004, 35: 121-133.