Vous êtes sur la page 1sur 21

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Flow and resin infusion: Theory and introduction


to PAM-RTM
Overview:
Practical aspects of resin infusion
Details and capabilities of the PAM-RTM code for resin infusion
simulation
Basic theory for fluid flow analysis (steady state)
o Finite Difference solution to the problem
o Finite Element solution to the problem
Tutorial examples on resin infusion
1

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Outline of Lecture

Details and comparison of some composites manufacturing methods:


o Wet lay-up
o Pre-pregs
o Liquid Resin Infusion
Introduction to resin infusion simulation:
o Basic theory
o Range of application
o Examples
Materials testing (for permeability)
Tutorials (using PAM-RTM)

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Outline of Lecture

Details and comparison of some composites manufacturing methods:


o Wet lay-up
o Pre-pregs
o Liquid Resin Infusion
Introduction to resin infusion simulation:
o Basic theory
o Range of application
o Examples
Materials testing (for permeability)
Tutorials (using PAM-RTM)

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Alternative composites manufacturing technologies

Hand (wet) lay-up


o
o
o
o
o

(+) Easy setup, low cost


(+) Any geometry
(-) Non-uniform properties
(-) Low fiber volume content
(-) VOC emissions (styrene)

Prepreg (autoclave)
o (-) High costs (material, freezer, autoclave,
heating)
o (-) Geometry complications
o (+) Uniform mechanical properties
o (+) High fiber volume content
o (+) No emissions

Resin Infusion: Something in between?

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

Comparing pre-preg and infusion composite technologies

Pre-pregs are pre-impregnated plies of fibre and resin


pressure

heat

Any fabric or
mat system

Polymer may be
thermoplastic or thermoset

Infusion technologies mix fibres and resin at the part manufacturing stage

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Pre-preg and infusion: Comparison of (usual) post curing methods

Pre-Preg
Hand or machine lay-up
Oven or Autoclave cure
and post cure
Autoclave

Resin infusion
Hand or machine lay-up
Room temperature or oven
cure

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Manufacture with Pre-pregs


1. Laying the plies: By hand or
automated methods (e.g. tape layers)
3. Apply heat and pressure cycle (usually
in an autoclave) to consolidate laminate

2. Stacking the plies and preparing for


consolidation (vacuum bagging)

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Manufacture with resin infusion: E.g. traditional RTM (closed mould)

EADS - Jensen (2003)

The important point here is that the gap between the tooling is fixed and constant
throughout infusion.
Large pressure may be used (for sufficiently strong tooling), but the liquid may have
to be pushed long distances though the fabric; probably leading to slow flow rates.

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Comparing RTM and LRI infusion processes

Resin Transfer
Moulding RTM

Pre-forming

Liquid Resin
Infusion LRI

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Resin infusion: Vacuum bagging


Styrofoam
Flow media
Styrofoam

Peel ply

Vacuum
bagging film
Fabric

To vacuum pump

Peel ply

Flow media

Mould with release agent

Sealant
tape

Different layers

Infusion
10

Final 10
part

Bagging film

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Typical Liquid Resin Infusion of a large part


Manufacturing steps:
1. Preform manufacture
2. Flow media and
vacuum bagging
3. Infusion
4. Final part

(2)

(3)

(1)

(4)

IFB Stuttgart
11

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

VARI application in the marine industry

VT Halmatic
12

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Infusion Examples from business Jets (courtesy IAI)

G150 Forward Belly Fairing-Woven Fabrics


and PMI Foam Core - In Service 5+ years

G250 Aft Wing/Fuselage FairingMonolithic NCF - in certification


13

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Another LRI example: Courtesy Piaggio Aerospace

14

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Prepreg versus Infusion: Advantages and disadvantages


Pre-Pregs and Tape Laying:
+ High Performance, high quality composites
+ Well established and well automated technology
- Expensive materials, short shelf life
- Slower manufacturing and autoclave curing/
consolidation (needs an Autoclave and long cycle
times
- Limited capabilities for part integration and
complex shapes

Liquid Resin Infusion:


+ Lower materials and manufacturing costs
+ Long materials shelf life (fabrics indefinate)
+ Complex shapes and parts integration possible
+ No autoclave needed and moderate cycle times
- Lower fibre volume fractions
- Lower materials performance
15

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Outline of Lecture

Details and comparison of some composites manufacturing methods:


o Wet lay-up
o Pre-pregs
o Liquid Resin Infusion
Introduction to resin infusion simulation:
o Basic theory
o Range of application
o Examples
Materials testing (for permeability)
Tutorials (using PAM-RTM)

16

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

The various resin infusion methods

The most common Liquid Infusion Methods are:


Resin Transfer Moulding (RTM)
Vacuum Assisted Resin Transfer Moulding (VARTM)
Injection Compression Moulding or Compression RTM
Structural Reaction Injection Moulding (SRIM)
Reinforced Reaction Injection Moulding (RRIM)
RTM Light
Resin Film Infusion

22

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Some infusion processes: Standard and more advanced


inlet tube
rubber joints

heating
tubes

heated resin

controlled motion
of the upper
mold wall

inlet
tube

heating tubes

preform

closed mold RTM

closed mould RTM

inlet
tube

heated RTM

heated RTM

flexible
membrane

injection - compression
injection-compression

(CRTM)

autoclave
controlled
pressure

inlet
tube

flexible
semi-permeable
membrane

vacuum outlets

23

Vacuum Assisted Resin Infusion


liquid resin infusion
(VARI) (VARI)

VARI with
autoclave
Autoclave
RTM

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Basic flow model: Darcys Law


-

resin
inlet

m3/s

m2

=
A

m2

m/s
section A

resin
outlet

Pa

Pas

K : permeability (m2)
: resin viscosity (Pa.s)

24

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Tensorial Darcys law for anisotropic flow


Principle permeabilities:

K1
[K ] = 0
0
y

0
K2
0

0
0
K 3

warp

p

kxx kxy kxz x
qx
p
1

qy = kxy k yy k yz y
k k k
q
z
xz yz zz p
z
vector q

permeability tensor [K]

x
thickness

weft

Fibre directions from simple geometric considerations


Or from a full preform draping and mapping operation
25

z
x
thickness

10

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Infusion simulation: Governing conditions and boundary conditions

26

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

PAM-RTM: Typical input and results (outputs)


OUTPUTS

INPUTS
Mesh of the part (mesh of the preform)
Process initial set-up
Injection point and vent positions
Injection pressure or flow rate as function of
time

Material
Reinforcement
Permeability tensor
Density
Heat conductivity tensor
Specific Heat
Permeability function of
thickness
Compressibility curve

Mold
Density
Heat conductivity tensor
Specific heat
27

Resin
Viscosity
Density
Heat conductivity
Specific Heat
Enthalpy
Kinetics Modeling

Resin &
Reinforcement
Capillarity
Micro-Macro void
function

Optimized
Injection strategy
Injection pressure or
flow rate
Molding temperature
Location of injection
gates, vents and
vacuum ports
Flow media position

Prediction of
Dry spots
Filling and curing times
Flow front
velocity/Fiber washing
Pressure applied to the
mold

11

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Some capabilities of State-of-the-Art infusion simulation

2D and 3D FEM modelling

Filling simulation using DARCYs law

Thermal modelling:
o

Pre-heating of the mold

3D heat conduction inside the mold

Source term

Contact Resistance

Curing modeling (Kamal Sourour model) during and after filling

Viscosity depending on temperature and curing degree

Permeability depending on shearing of the reinforcement and fiber content

User defined model for viscosity and curing

Use of draping information regarding reinforcement deformation in order to


modify permeability:
o

PAM-FORM, QUIK-FORM, CATIA Composites Part Design, FiberSim

Full integration of PAM-QUIKFORM

28

IFB

28

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Typical simulation results


Filling prediction 2D

Resin degree of cure

Temperature history

Filling prediction 3D

29

12

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Application example: The CEC TECABS project 1999-2003


Injection test and simulation of an Automotive floorpan:
Filling: 40 %

Flowrate: 39 g/s

Filling: 80 %

Filling: 100 %

30

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Example optimisation: Injection positions and time (RTM example)


Example (Cases 1 and 2) consider alternative injection strategies:

Line
injections

Point injection

Line injection

Case 1

Case 2

31

13

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion
vent

Example RTM injection: Process and simulation

Example for end


injection

racers
START

injection
INTERMEDIATE
Potential
dry spots

Experimental setup

FINAL

Example for central


injection
vents

Final part
injection

32

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Validation example
Test versus simulation, courtesy ETH Zrich:

ETH

Vaidation using central injection and geometrical obatacles; in collboration


with industrial partners (EADS, FORD, ALCAN )
33

14

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Texcomp presentation

34

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Outline of Lecture

Details and comparison of some composites manufacturing methods:


o Wet lay-up
o Pre-pregs
o Liquid Resin Infusion
Introduction to resin infusion simulation:
o Basic theory
o Range of application
o Examples
Materials testing (for permeability)
Tutorials (using PAM-RTM)

38

15

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Measuring in plane permeability

39

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Measuring through thickness permeability

Kz testing by point infusion in thick


stack
Nedanov method
o Time to first touch of bottom by resin

Interpretation of results
o Adaptation of Nedanov solution
o PAM-OPT
 iterations of PAM-RTM with
different K values
 Match time/flow front
 Response Surface Method /
Genetic Algorithm

40

16

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Outline of Lecture

Details and comparison of some composites manufacturing methods:


o Wet lay-up
o Pre-pregs
o Liquid Resin Infusion
Introduction to resin infusion simulation:
o Basic theory
o Range of application
o Examples
Materials testing (for permeability)
Tutorials (using PAM-RTM)

98

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Infusion simulation: Tutorial examples


Tutorials:
Exercise 1 Central injection of a composite plate with a hole
Exercise 2 Rectangular plate with race tracking
Exercise 3 Complex geometry with race tracking
Exercise 4 T-Junction with orthotropic permeability and fibre
orientations
Exercise 5 - Mapping a sheared fabric on to an infusion mesh for
infusion and infusion simulation

99

17

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Exercise 1: Central injection of a composite plate with a hole


See Exercise 1 directory for this lecture on the L drive The
exercise description and necessary inputs datasets are given
Objectives:

100

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Exercise 2: Rectangular plate with race tracking


See Exercise 2 directory for this lecture on the L drive The
exercise description and necessary inputs datasets are given
Objectives:

101

18

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Exercise 3: Complex geometry with race tracking


See Exercise 3 directory for this lecture on the L drive The
exercise description and necessary inputs datasets are given
Objectives:

102

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Exercise 4: T-Junction with orthotropic permeability and fibre orientations


See Exercise 4 directory for this lecture on the L drive The
exercise description and necessary inputs datasets are given
Objectives: Definition of orthotropic permeability and fibre directions. Simulation of
flow and prediction of flow through the wickle

103

19

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

Exercise 5: Infusing a draped (deformed) fabric


See Exercise 5 directory for this lecture on the L drive The
exercise description and necessary inputs datasets are given
The analysis steps:

The geometry
being analysed

104

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

IFB

Composites modelling:
Practice, theory and simulation of resin infusion

The mapping step

Import the deformed mesh from a


draping simulation drape.dsy

Import the mesh for the injection


simulation drape_start.unv

105

Shear information is mapped


on to the injection mesh

20

IFB

A.K. Pickett, 2013-2014


Institut fr Flugzeugbau, University Stuttgart

Composites modelling:
Practice, theory and simulation of resin infusion

Computing local permeability and porosity distributions, assigning


process parameters and final results for an infusion simulation

Filling times for the infusion


simulation
e.g. Porosity distribution

106

21

Vous aimerez peut-être aussi