Integrated Computational Material Design for PMC Manufacturing with Trapped Rubber

As the use of continuous fiber polymer matrix composites expands into new fields, there is a growing need for more sustainable manufacturing processes. An integrated computational material design framework has been developed, which enables the design of tailored manufacturing systems for polymer matrix composite materials as a sustainable alternative to achieving high-quality components in high-rate production. Trapped rubber processing achieves high pressures during polymer matrix composite processing, utilizing the thermally induced volume change of a nearly incompressible material inside a closed cavity mold. In this interdisciplinary study, the structural analysis, material science and manufacturing engineering perspectives are all combined to determine the mold mechanics, and the manufacturing process in a cohesive and iterative design loop. This study performs the coupled thermo-mechanical analysis required to simulate the transients involved in composite manufacturing and the results are compared with a previously developed test method. The internal surface pressure and temperatures are computed, compared with the experimental results, and the resulting design process is simulated. Overall, this approach maintains high-quality consolidation during curing while allowing for the possibility for custom distributions of pressures and temperatures. This can lead to more sustainable manufacturing by reducing energy consumption and improving throughput.