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Modelling of Process-Induced Deformation for Composite Parts Considering Tool-Part Interaction
Wei Qiao1, Weixing Yao1,2
1Key Laboratory of Fundamental Science for National Defense-Advanced Design Technology of Flight Vehicle, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China.
Materials (Basel, Switzerland)
|October 14, 2020
Summary
This study introduces a 3D numerical model to predict composite part deformation caused by tool-part interaction. The model accurately predicts spring-in angles, offering insights into process-induced deformation in complex composite structures.
Area of Science:
- Materials Science
- Mechanical Engineering
- Computational Modeling
Background:
- Residual stresses in composite manufacturing arise from thermal expansion differences between tools and parts.
- These stresses lead to significant process-induced part deformation, particularly in complex shapes.
- Existing models often do not fully capture the impact of tool-part interaction on deformation.
Purpose of the Study:
- To develop and validate a 3D numerical model for predicting deformation in complex-shape composite parts.
- To incorporate the influence of tool-part interaction and residual stresses into the prediction model.
- To analyze the effect of various structural parameters on the spring-in angle of composite parts.
Main Methods:
- A 3D numerical model was developed, enhancing a path-dependent model with residual stresses from tool-part interaction.
- A simplified self-consistent micromechanics model was used to predict composite mechanical properties.
- The model's predictions for spring-in angles were compared against experimental data for L- and U-shaped parts.
- A parametric study quantified the influence of part structural parameters on spring-in angles.
Main Results:
- The proposed numerical model demonstrated good agreement with experimental spring-in angles for L- and U-shaped parts.
- The model successfully predicted deformation influenced by tool-part interaction and residual stresses.
- Part thickness was found to decrease spring-in angles from chemical shrinkage and tool-part interaction.
- Spring-in angles due to thermal contraction remained relatively constant with increasing part thickness.
Conclusions:
- The developed 3D numerical model is valid for predicting process-induced deformation in complex composite parts.
- Tool-part interaction significantly contributes to residual stresses and subsequent part deformation.
- Understanding the influence of structural parameters like part thickness is crucial for mitigating spring-in effects in composite manufacturing.
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