Theoretical and experimental validation of critical thermal properties of advanced vacuum bagging for composite manufacturing

Abstract

The vacuum bagging is a common but critical step of various manufacturing process chains for Carbon/Glass Fibre reinforced polymers (C/GFRP). Whilst developing a new generation of vacuum bagging, significant efforts have been made to deeply understand the relevant physics fields, process variables involved and to provide predictive approaches to support dimensioning and scaling exercises prior to implementation into real production process. Main features of the new bagging system are, (1) the reduction of material diversity through merging of various properties within one single layer and, (2) the suppression of critical folding steps by using thermoforming for pre-shaping purposes. This paper will mainly focus on considerations of heat transfer during the pre-shaping of the film, directly on the CFRP part short before the curing step. For the better risk assessment of the short time exposition of an uncured composite part to the heat flow, a problem of transient coupled field analysis involving heat transfer via conduction, convection and radiation is formulated and solved by using Finite Element Analysis in COMSOL under consideration of realistic process conditions. Further a section dedicated to the comparison of the obtained results with measurements performed on a system including an IR-emitter, the bagging material, a ground plate and in some studies as well a CFRP sample is included. During the study the influence of time, power output of the emitter, distance between emitter and surface as well as irradiation angle has been assessed including a comparison of simulated results and performed measurements.