Flexible low-cost tooling solutions for a one-shot resin infusion of a 3D woven and multi-textile preform

Budwal, Nikita; Kasper, Kent; Goering, J.; Ward, Carwyn

doi:10.1016/j.promfg.2020.10.120

Cited by 8 publications

(14 citation statements)

References 9 publications

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“…Six components were manufactured with a multi-textile pi-stiffened geometry, representative of a stiffened aerostructure. The components consisted of a 3D woven pi-preform on a non-crimp fabric (NCF) skin and were infused as per the manufacturing details in [1]. The pi-preforms were woven by Albany Engineered Composites, Inc. with Hexcel IM7 TM 6K and 12K carbon fibre.…”

Section: Materials and Manufacturementioning

confidence: 99%

“…The preforms were infused at 120 • C with Solvay PRISM™ EP2400 RTM resin and cured at 180 • C for 2 h. Table 2 lists the manufacturing data for the infusions. Refer to [1] for additional information on insert design and manufacture, and pi-NCF forming and moulding process steps.…”

Section: Materials and Manufacturementioning

confidence: 99%

“…Co-infused assemblies of mid-large aerostructures (i.e., integrated door surrounds, wing skins, fuselage sections, etc.) have the potential for significant reductions in weight and labour, due to a reduced need for bonding and assembly [1]. Obtaining right-first-timemanufacture (RFTM) of these large scale co-infused assemblies is difficult to achieve without correctly identifying and understanding potential sources of defects or scrapped parts early in their design [2].…”

Section: Introductionmentioning

confidence: 99%

“…For manufacturing co-infused assemblies, an effective knowledge management system would allow designers to foresee manufacturing problems with infusion or tooling strategies, prior to manufacture [5]. There are two hurdles to developing such a system: (1) Capturing the manufacturing knowledge associated with different infusion and tooling strategies, and component materials and geometries;…”

Section: Introductionmentioning

confidence: 99%

“…Multi-textile preforms can be fabricated into a range of complex geometries, incorporating features with variable thicknesses, contours, and seams. By co-infusing these preforms, weight and costs can be saved, as exemplified by the examples listed in Table 1 [1].…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Tooling and Infusion Design Strategies to Reduce Trade-Offs in Forming and Infusion Quality of Multi-Textile CFRPs

Budwal

Kasper²,

Goering³

et al. 2022

JMMP

Self Cite

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Achieving right-first-time-manufacture (RFTM) of co-infused textile assemblies is challenging, without improving the accessibility to design knowledge of trade-offs between different tooling and infusion strategies. As demonstrated in previous work, the choice between a flexible or rigid mould material can result in trade-offs between dimensional accuracy and geometrical precision. Similarly, the choice of an infusion strategy can result in trade-offs in infusion quality and time. Building on past work, an investigation into forming variability across the length of six co-infused multi-textile components, with three different tooling inserts and two infusions set-ups, was conducted. To quantitatively assess variation, a method adapting principles of statistical process control was employed to analyse the yarn crimp measured from high-resolution cross-sectional scans of the components. The results were compared to a geometrical and dimensional analysis of the manufactured parts presented in a previous work. The analysis represents a method for capturing forming differences in textile preforms, which can be used to inform designs for the manufacture of textile CFRPs. The results were used to improve a hybrid rigid-flexible tooling design for an infused multi-textile component.

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Section: Materials and Manufacturementioning

confidence: 99%

Section: Materials and Manufacturementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Tooling and Infusion Design Strategies to Reduce Trade-Offs in Forming and Infusion Quality of Multi-Textile CFRPs

Budwal

Kasper²,

Goering³

et al. 2022

JMMP

Self Cite

View full text Add to dashboard Cite

show abstract

The mechanical effect of monitoring and controlling the impregnation in the resin infusion process

2022

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Nowadays, most of industries are optimizing their processes to make their products more competitive. In the composites manufacturing industry, there is a big gap between the almost fully automated processes and those which require an intensive labor‐work. Although it has many advantages, the resin infusion process is characterized for its lack of automation. As a consequence, the results are strongly dependent on the process boundaries, the operator skills and expertise, and the result is usually far away from the optimum. In this work, the application of a novel methodology and its capability to maximize the mechanical properties of infusion‐manufactured composite materials is presented. After manufacturing stitched and unstitched materials at different impregnation velocities, an optimum value was assessed. The application of this value during the manufacture has increased the tensile and impact properties.

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From microscale to mesoscale: The non-linear behavior prediction of 3D braided composites based on the SCA2 concurrent multiscale simulation

Gao

et al. 2021

Composites Science and Technology

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Flexible low-cost tooling solutions for a one-shot resin infusion of a 3D woven and multi-textile preform

Cited by 8 publications

References 9 publications

Tooling and Infusion Design Strategies to Reduce Trade-Offs in Forming and Infusion Quality of Multi-Textile CFRPs

Tooling and Infusion Design Strategies to Reduce Trade-Offs in Forming and Infusion Quality of Multi-Textile CFRPs

The mechanical effect of monitoring and controlling the impregnation in the resin infusion process

From microscale to mesoscale: The non-linear behavior prediction of 3D braided composites based on the SCA2 concurrent multiscale simulation

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