Process Simulation & Optimization for Thin-Ply Composites

The proposed innovation is a process simulation tool for thin ply composites. This simulation tool will represent major process attributes and allow users to make low risk, high quality parts. Furthermore, this tool will help to guide selection of tooling materials and processing conditions to avoid unwanted distortion, which is an issue that plagues thin ply composite parts. Phase II will focus on expanding the developed Process Induced Distortion (PID) simulation workflow, configuration and setup tool, and material characterizations to additional thermoset composite part tooling designs and new thermoplastics composite based part configurations using Continuous Compression Modeling (CCM) processing based on Convergents COMPRO framework. Using COMPRO with ABAQUS or ANSYS, the setup tool, methodology, workflow, and necessary characterizations (material, process conditions, and boundary conditions) the approach will be capable of capturing the manufacturing process-induced deformations in thin-ply composite structures. The proposed improvements will result in a better understanding of the contribution of material selection, material property evolution, tooling material properties, tool part interaction, and process conditions to the internal stress evolution and final part distortion. Thermoplastic-specific properties like crystallization morphology will be characterized over the process range of interest to quantify their impact on part distortion related to the CCM process. This understanding will be used to guide material, tool, and process changes to reduce variation and meet final part geometric requirements. This methodology and associated material characterizations, once validated, can be applied to similar structures and materials, both existing and future, considered by government and industry reducing development time (both in design and manufacturing test trials) where trade-off between geometry, performance, cycle time and costs are considered. This Phase II project proposes a process simulation tool that addresses process-induced distortion of thin composite structures, as the spring-in effect is a known phenomenon that affects part accuracy during fabrication. Using COMPRO within a general-purpose FE environment, the methodology, workflow and characterizations will be identified and demonstrated to capture the process-induced distortions and residual stresses adapted to thin-ply composite structures. The ability to model the process induced distortions in these types of very thin composites did not exist prior to Phase I work. The simulation tool will represent major process attributes and enable users to improve the design and make low risk, high quality parts. Furthermore, this tool will help to guide selection of tooling materials and processing conditions to avoid unwanted distortion, which is an issue that plagues thin ply composite parts. Once validated, this tool can be applied to similar structures and materials of interest to government and industry, reducing development time, costs and production risks. Technical Objectives: Adapt Phase I simulation tools and process-induced distortion (PID) for new CTM sizes and shape profiles Review and characterize new processing and tooling materials Develop streamlined toolset for model setup, run, and analysis of PID in CTM structures Measure PID in representative CTM parts for both thermoset and thermoplastic parts/processes Characterize continuous compression molding (CCM) process (thermal and pressure) Develop and execute a simulation methodology for processing of thermoplastic structures using CCM Characterize a thermoplastic composite material for CCM processing Proposed Deliverables: Reports and data summarizing CTM distortions for thermoset and thermoplastic parts Reports and data summarizing materials characterization of thermoplastic material of interest for CCM processing Simulation plan for building additional thermoset CTM structures Prototype toolset for streamlining and automating PID analysis in CTM structures Report summarizing the key physics of the CCM process and methodology for modeling this process Example simulations for thermoset and thermoplastic CTM models

Reduced overall distortion and variation for a range thermoset or thermoplastic composite tubular mast geometries, materials, and manufacturing techniques. Material characterizations will be of benefit for use in the simulation of part and process and design optimization of any part/tool/process configuration developed using the same or similar materials. Simulation methodologies and tools developed for CCM processes can be used to analyze and optimize part and process designs for a wide range of both space, air, and ground based applications. Characterized material models can be used in the simulation and optimization of process and part designs of any part / tool /process configuration developed using the same or similar materials.  Methodologies developed to simulate and optimize CCM processes and part designs can result in performance and yield improvements in any application where CCM processes are applicable.

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