Virtual manufacturing of composite aerostructures

D’Mello, Royan J.; Maiarù, Marianna; Waas, Anthony M.

doi:10.1017/aer.2015.19

Cited by 35 publications

(22 citation statements)

References 55 publications

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“…Thus, the LU scanning method described here is a great improvement over current tools to characterize impact damage at multiple size scales, enabling in-situ imaging (i.e., without sample excision) at least within the upper part of an in-depth damage distribution on a minute time scale. We hope, and believe, that the damage structure imaged with high-resolution LU scanning in the upper composite layers can be used in advanced mechanical models [59] , [60] , [61] , [62] to predict damage propagation into deeper layers and evaluate residual life of entire components subjected to impact loading. This hypothesis will be tested in future studies.…”

Section: Discussionmentioning

confidence: 99%

High resolution imaging of impacted CFRP composites with a fiber-optic laser-ultrasound scanner

et al. 2016

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Damage induced in polymer composites by various impacts must be evaluated to predict a component’s post-impact strength and residual lifetime, especially when impacts occur in structures related to human safety (in aircraft, for example). X-ray tomography is the conventional standard to study an internal structure with high resolution. However, it is of little use when the impacted area cannot be extracted from a structure. In addition, X-ray tomography is expensive and time-consuming. Recently, we have demonstrated that a kHz-rate laser-ultrasound (LU) scanner is very efficient both for locating large defects and evaluating the material structure. Here, we show that high-quality images of damage produced by the LU scanner in impacted carbon-fiber reinforced polymer (CFRP) composites are similar to those produced by X-ray tomograms; but they can be obtained with only single-sided access to the object under study. Potentially, the LU method can be applied to large components in-situ.

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Section: Discussionmentioning

confidence: 99%

High resolution imaging of impacted CFRP composites with a fiber-optic laser-ultrasound scanner

et al. 2016

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“…The residual heat from the nonisothermal DSC on the 40 C isothermally cured specimen, was 21.6 J/g indicating that the resin was not fully cured after 12 h. For the two experiments performed at 50 and 60 C, ΔH res was zero, which means that the reaction was already completed after the isothermal DSC. The calculated values of α max , ΔH iso , and ΔH res , using Equation 10and (11), are reported in Table 2.…”

Section: Cure Kinetics Characterizationmentioning

confidence: 99%

“…[6][7][8] Therefore, predictive models that enable the tracing of the temperature and degree of cure evolution during the cure cycle of thermosets are essential to ensure good mechanical properties of the final product. Cure simulations of thick thermosetting composites can be extensively found in the literature [9][10][11][12][13][14][15] and finite element (FE) simulations have also been developed to predict residual stresses and post-cured mechanical properties in thermoset composites. [10][11][12][13] First attempts to solve numerically the two-dimensional convection-diffusion heat equation, coupled with the internal heat generated by the exothermic reaction, were made by the use of the finite difference method.…”

Section: Introductionmentioning

confidence: 99%

“…Cure simulations of thick thermosetting composites can be extensively found in the literature [9][10][11][12][13][14][15] and finite element (FE) simulations have also been developed to predict residual stresses and post-cured mechanical properties in thermoset composites. [10][11][12][13] First attempts to solve numerically the two-dimensional convection-diffusion heat equation, coupled with the internal heat generated by the exothermic reaction, were made by the use of the finite difference method. 14,15 Later, 2D and 3D FE codes were developed to address problems with complex geometries by several authors.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Cure simulations of thick adhesive bondlines for wind energy applications

Cassano

Dev

Maiarù

et al. 2020

J of Applied Polymer Sci

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Curing of adhesive bondlines is a critical and time-consuming operation in wind turbine blade manufacturing. Significant variation in adhesive thickness can lead to important differences in thermal histories trough the adhesive bonds due to the exothermic nature of the cure process. Reducing bondline cure cycle time and avoiding adhesive overheating are two competing factors in the design of cure temperature cycles. Predictive models on the impact of adhesive thickness variability in bondline cure temperature cycle is currently limited. Adhesive curing and temperature evolution can be simulated by finite element (FE) models coupling the heat transfer problem with the cure kinetics of the adhesive. The cure kinetics of the adhesive system was characterized by isothermal differential scanning calorimetry experiments and implemented in the FE software Abaqus/CAE by user subroutines. Predictions from the FE model were validated experimentally against temperature readings from the curing of 10, 20, and 30 mm thick adhesive bondlines. To highlight the role that predictive models potentially have in the optimization of bondline cure cycles a 2D cross section model representing the trailing edge of a wind turbine blade was used as case study. It was demonstrated that computational models enable customizing cure profiles for nonuniform adhesive thicknesses, ensuring fully cured bondlines with acceptable mechanical properties.

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“…Most layer-by-layer models are very simple geometries for mechanistic structural analyses. Previous studies on modeling of composite laminates mostly focused on simulation of composite structural behavior using FEA in the sense of mathematical representations of microstructures for "virtual testing" [5,7,12,14]. Recently, a method to describe isogeometric analysis of shell models of composite laminae with curved shapes using NURBS representations in order to predict the failure mechanisms has been studied by Guo and Ruess [8].…”

Section: Model Builder Apimentioning

confidence: 99%

An integrated framework for solid modeling and structural analysis of layered composites with defects

Bingol

Schiefelbein

Grandin

et al. 2019

Computer-Aided Design

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Laminated fiber-reinforced polymer (FRP) composites are widely used in aerospace and automotive industries due to their combined properties of high strength and low weight. However, owing to their complex structure, it is difficult to assess the impact of manufacturing defects and service damage on their residual life. Non-destructive evaluation (NDE) of composites using ultrasonic testing (UT) can identify the presence of defects. However, manually incorporating the damage in a CAD model of a multi-layered composite structure and evaluating its structural integrity is a tedious process. We have developed an automated framework to create a layered 3D CAD model of a composite structure and automatically preprocess it for structural finite element (FE) analysis. In addition, we can incorporate flaws and known composite damage automatically into this CAD model. The framework generates a layer-by-layer 3D structural CAD model of the composite laminate, replicating its manufacturing process. The framework can create non-trivial composite structures such as those that include stiffeners. Outlines of structural defects, such as delaminations detected using UT of the laminate, are incorporated into the CAD model between the appropriate layers. The framework is also capable of incorporating fiber/matrix cracking, another common defect observed in fiber-reinforced composites. Finally, the framework can preprocess the resulting 3D CAD models with defects for direct structural analysis by automatically applying the appropriate boundary conditions. In this paper, we show a working proof-of-concept of the framework with capabilities of creating composite structures with stiffeners, incorporating delaminations between the composite layers, and automatically preprocessing the CAD model for finite element structural analysis. The framework will ultimately aid in accurately assessing the residual life of the composite and making informed decisions regarding repairs. AbstractLaminated fiber-reinforced polymer (FRP) composites are widely used in aerospace and automotive industries due to their combined properties of high strength and low weight. However, owing to their complex structure, it is difficult to assess the impact of manufacturing defects and service damage on their residual life. Non-destructive evaluation (NDE) of composites using ultrasonic testing (UT) can identify the presence of defects. However, manually incorporating the damage in a CAD model of a multi-layered composite structure and evaluating its structural integrity is a tedious process. We have developed an automated framework to create a layered 3D CAD model of a composite structure and automatically preprocess it for structural finite element (FE) analysis. In addition, we can incorporate flaws and known composite damage automatically into this CAD model. The framework generates a layer-by-layer 3D structural CAD model of the composite laminate, replicating its manufacturing process. The framework can create non-trivial composite structures such as those tha...

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Virtual manufacturing of composite aerostructures

Cited by 35 publications

References 55 publications

High resolution imaging of impacted CFRP composites with a fiber-optic laser-ultrasound scanner

High resolution imaging of impacted CFRP composites with a fiber-optic laser-ultrasound scanner

Cure simulations of thick adhesive bondlines for wind energy applications

An integrated framework for solid modeling and structural analysis of layered composites with defects

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