No abstract

For large composite structures, such as wind turbine blades, thick laminates are required to withstand large in-service loads. During the manufacture of thick laminates, one of the challenges met is avoiding process-induced shape distortions and residual stresses. In this paper, embedded fibre Bragg grating sensors are used to monitor process-induced strains during vacuum infusion of a thick glass/epoxy laminate. The measured strains are compared with predictions from a cure hardening instantaneous linear elastic (CHILE) thermomechanical numerical model where different mechanical boundary conditions are employed. The accuracy of the CHILE model in predicting process-induced internal strains, in what is essentially a viscoelastic boundary value problem, is investigated. A parametric study is furthermore performed to reveal the effect of increasing the laminate thickness. The numerical model predicts the experimental transverse strains well when a tied boundary condition at the tool/part interface is used and the tool thermal expansion is taken into account. However, the CHILE approach is shown to overestimate residual strains after demoulding because of the shortcomings of the model in considering viscoelastic effects. The process-induced strain magnitude furthermore increases when the laminate thickness was increased, owing mainly to a decrease in through-thickness internal transverse stresses.In situ process-induced strains during curing of thick laminate M. W. Nielsen et al.In situ process-induced strains during curing of thick laminate M. W. Nielsen et al.

Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the present article, examples of this will be presented. The cases are chosen with the aim of showing the diversity in the field of modelling of manufacturing processes as regards process, materials, generic disciplines as well as length scales: (1) modelling of tape casting for thin ceramic layers, (2) modelling the flow of polymers in extrusion, (3) modelling the deformation process of flexible stamps for nanoimprint lithography, (4) modelling manufacturing of composite parts and (5) modelling the selective laser melting process. For all five examples, the emphasis is on modelling results as well as describing the models in brief mathematical details. Alongside with relevant references to the original work, proper comparison with experiments is given in some examples for model validation.

A holistic approach to strain monitoring in fibre-reinforced polymer composites is presented using embedded fibre Bragg grating sensors. Internal strains are monitored in unidirectional E-glass/epoxy laminate beams during vacuum infusion, curing, post-curing and subsequent loading in flexure until failure. The internal process-induced strain development is investigated through use of different cure schedules and tool/part interactions. The fibre Bragg grating sensors successfully monitor resin flow front progression during infusion, and strain development during curing, representative of the different cure temperatures and tool/part interfaces used. Substantial internal process-induced strains develop in the transverse fibre direction, which should be taken into consideration when designing fibre-reinforced polymer laminates. Flexure tests indicate no significant difference in the mechanical properties of the differently cured specimens, despite the large differences in measured residual strains. This indicates that conventional flexure testing may not reveal residual strain or stress effects at small specimen scale levels. The internal stresses are seen to influence the accuracy of the fibre Bragg gratings within the loading regime. This study confirms the effectiveness of composite life cycle strain monitoring for developing consistent manufacturing processes.

Test control is traditionally performed by a feedback signal from a displacement transducer or force gauge positioned inside the actuator of a test machine. For highly compliant test rigs, this is a problem since the response of the rig influences the results. It is therefore beneficial to control the test based on measurements performed directly on the test specimen. In this paper, fibre Bragg grating (FBG) and Digital Image Correlation (DIC) are used to control a test. The FBG sensors offer the possibility of measuring strains inside the specimen, while the DIC system measures strains and displacement on the surface of the specimen. In this paper, a three‐point bending test is used to demonstrate the functionality of a control loop, where the FBG and DIC signals are used as control channels. The FBG strain control was capable of controlling the test within an error tolerance of 20 µm m−1. However, the measurement uncertainty offered by the FBG system allowed a tolerance of 8.3 µm m−1. The DIC displacement control proved capable of controlling the displacement within an accuracy of 0.01 mm.