Numerical simulation and experimental studies of mandrel effect on flow-compaction behavior of CFRP hat-shaped structure during curing process

Li, Shujian; Zhan, Lihua; Chang, Tengfei

doi:10.1016/j.acme.2018.04.008

Cited by 22 publications

(9 citation statements)

References 16 publications

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“…When fabricating a pressure vessel, reinforcing material is laid out along a specified trajectory on a rotating mandrel, which determines the internal geometry of the prod-uct [6,7]. A mandrel should have a shape and size that precisely matches the shape and size of the inner surface of a filament wound product, and also effectively absorb the force and temperature effects during winding and curing of the binder.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore in the context of this article it is worth highlighting the contribution of some works to this area of research. The work by Shujian Li et al [7] presents a theoretical basis for the manufacturing technology used to fabricate hat-shaped structures from carbon fiber reinforced plastic. The authors propose a multiphysics model of field interaction, which takes into account the influence of mandrel design.…”

Section: Introductionmentioning

confidence: 99%

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ANSYS Simulation of the Thermomechanical Behavior of a Large-Sized Composite Mandrel with Consideration of Viscoelasticity

2022

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The article addresses the modeling of the process of manufacturing a large-sized shell, given the thermomechanical behavior and viscoelasticity of the composite mandrel. The results of the experimental identification of viscoelasticity parameters of the examined material are presented. A numerical algorithm for adapting the experimental data for the ANSYS Mechanical APDL finite element analysis package is proposed. A Prony series expansion of the relaxation kernel is used as a model for describing the material behavior. The effect of temperature on the rate of relaxation processes is taken into account through the application of a temperature-time analogy according to the Williams–Landel–Ferry formula. The selected model with the calculated parameters was implanted into the commercial package of ANSYS Mechanical APDL. Simulation of two process steps of manufacturing a large-sized product was performed: winding and heat treatment of the shell. For this purpose, the quasistatic problem of mechanics and unsteady thermal conduction under conditions of convective heat transfer were solved by the finite element method. The influence of thermomechanical behavior of the mandrel material on the normal pressure acting on the mandrel surface as a function of temperature and force factors was estimated quantitatively and qualitatively. It was found that with respect to the nonlinear behavior of the composite material, the pressure level decreases by 50% compared to the case of using models of elastic behavior. This result justifies the importance of using complex models of material behavior in studying long-term technological processes, especially those associated with high-temperature effects.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

ANSYS Simulation of the Thermomechanical Behavior of a Large-Sized Composite Mandrel with Consideration of Viscoelasticity

2022

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“…Xie et al made a rubber mandrel with different thicknesses to make a cap girder and studied the influence of the different rubber mandrels on the thickness error of the cap girder [18]. Li et al studied the influence of a rubber mandrel with a middle opening and its air pressure on the quality of cap girder through simulation [19]. Although this rubber mandrel can be demolded by its softness, there might be uncontrollable deformation of the external prepreg during curing, finally affecting the accuracy of the formed structure.…”

Section: Introductionmentioning

confidence: 99%

Thermoplastic Mandrel for Manufacturing Composite Components with Complex Structure

Jing

Chen

et al. 2021

Aerospace

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This study was to solve the mandrel demolding problem after curing the composite component with complex structure. In this paper, a reusable thermoplastic mandrel with heating softening characteristics was developed by resin transfer molding (RTM). The glass transition temperature (Tg), surface roughness, and reusability of the mandrel, as well as the shape, surface roughness, thickness uniformity, and internal quality of the formed structure, were tested. The result showed that the Tg of the mandrel was between 80 and 90 °C and the surface roughness was less than Ra 0.5 μm. Additionally, the mandrel can be recycled and can still maintain a good shape after 20 times of deformation. By using this method, the demolding process can be realized by heating and softening the mandrel. The profile error of the formed structure was within 0.5 mm, the surface roughness was less than Ra 0.5 μm, the thickness error was within 0.2 mm, and the average porosity of the upper and lower halves of composite parts was 0.72% and 0.61%. All those data showed that the formed part was in good shape and of good quality. The thermoplastic mandrel can solve the demolding problem of composite materials with complex shapes.

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“…The proportion of carbon fiber reinforced polymer composites (CFRP) used in the new generation of aircraft have reached 50%, because it can reduce the weight of the structural components, resist corrosion and bear high loads. However, CFRP is difficult to machine because of its continuity, inhomogeneity and anisotropy, as well as its strong abrasion during machining processing [1,2]. Therefore, the choice of cutting tools and processing parameters are very important in cutting such materials [3,4].…”

Section: Introductionmentioning

confidence: 99%

Precise Design of Drill Structure Based on Cutting Force Distribution Alone Cutting Edge in CFRP Drilling

Qiu

et al. 2021

Preprint

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At present, the problems that need to be solved urgently in CFRP drilling are delamination and tool wear, which are closely related to the distribution of cutting force on the cutting edge. The aim of this paper is to present a method to analyze the cutting force distribution on the main cutting edge of the drill. This method applies to the analysis of the drilling performance of double point angle (DPA) drill and to optimize the step drill structure for CFRP drilling. Both of these applications prove the correctness of the analysis method. According to the calculation model of the rake angle of the main cutting edge of the twist drill and the cutting force prediction model, the distribution model of the cutting force on the main cutting edge is established. This method reveals the basic reason why the thrust force increases linearly when a single main cutting edge cuts into the workpiece. In the process of analyzing the drilling performance of the DPA drill, the edge force coefficient is used to represent the thrust force, and the application environment of the drill with a different structure is analyzed. Based on the distribution characteristics of the axial force on the main cutting edge, the step ratio of the step drill is optimized. This method can optimize the step ratio of the step drill. This method can be employed to optimize the step ratio of any structure step drill.

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Numerical simulation and experimental studies of mandrel effect on flow-compaction behavior of CFRP hat-shaped structure during curing process

Cited by 22 publications

References 16 publications

ANSYS Simulation of the Thermomechanical Behavior of a Large-Sized Composite Mandrel with Consideration of Viscoelasticity

ANSYS Simulation of the Thermomechanical Behavior of a Large-Sized Composite Mandrel with Consideration of Viscoelasticity

Thermoplastic Mandrel for Manufacturing Composite Components with Complex Structure

Precise Design of Drill Structure Based on Cutting Force Distribution Alone Cutting Edge in CFRP Drilling

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