Fast processing and continuous simulation of automotive structural composite components

A review of numerical models for 3D woven composite reinforcements

Although good progress was made by two international benchmark exercises on in-plane permeability, existing methods have not yet been standardized. This paper presents the results of a third benchmark exercise using in-plane permeability measurement, based on systems applying the radial unsaturated injection method. 19 participants using 20 systems characterized a non-crimp and a woven fabric at three different fiber volume contents, using a commercially available silicone oil as impregnating fluid. They followed a detailed characterization procedure and also completed a questionnaire on their set-up and analysis methods. Excluding outliers (2 of 20), the average coefficient of variation (cv) between the participant?s results was 32% and 44% (non-crimp and woven fabric), while the average cv for individual participants was 8% and 12%, respectively. This indicates statistically significant variations between the measurement systems. Cavity deformation was identified as a major influence, besides fluid pressure / viscosity measurement, textile variations, and data analysis.

/pdf/in-plane-permeability-characterization-of-engineering-g8mhic4tka.pdf

In-plane permeability characterization of engineering textiles based on radial flow experiments: A benchmark exercise

For mass production of structural composites, use of different textile patterns, custom preforming, room temperature cure high performance polymers and simplistic manufacturing approaches are desired. Woven fabrics are widely used for infusion processes owing to their high permeability but their localised mechanical performance is affected due to inherent associated crimps. The current investigation deals with manufacturing low-weight textile carbon non-crimp fabrics (NCFs) composites with a room temperature cure epoxy and a novel liquid Methyl methacrylate (MMA) thermoplastic matrix, Elium®. Vacuum assisted resin infusion (VARI) process is chosen as a cost effective manufacturing technique. Process parameters optimisation is required for thin NCFs due to intrinsic resistance it offers to the polymer flow. Cycles of repetitive manufacturing studies were carried out to optimise the NCF-thermoset (TS) and NCF with novel reactive thermoplastic (TP) resin. It was noticed that the controlled and optimised usage of flow mesh, vacuum level and flow speed during the resin infusion plays a significant part in deciding the final quality of the fabricated composites. The material selections, the challenges met during the manufacturing and the methods to overcome these are deliberated in this paper. An optimal three stage vacuum technique developed to manufacture the TP and TS composites with high fibre volume and lower void content is established and presented.

Optimizing Polymer Infusion Process for Thin Ply Textile Composites with Novel Matrix System.

A unit cell based Computational Fluid Dynamics model is presented for predicting permeability of multilayer fabric structures. In Liquid Composites Moulding processes, fabric lay-ups undergo significant manufacture-induced deformation, combining compression, shear, and inter-layer nesting. Starting from the configuration of un-deformed fabric, the deformation is simulated geometrically by accounting for self-imposed kinematic constraints of interweaving yarns. The geometrical modelling approach is implemented in the open-source software TexGen. The permeability tensor is retrieved from flow analysis in ANSYS/CFX, based on TexGen voxel models. Using only measured geometrical data for un-deformed fabrics, deformed plain weave fabric and twill weave fabric lay-ups were modelled and their permeability tensors predicted. Comparison with experimental data demonstrates the generally good accuracy of predictions derived from the proposed numerical method.

Numerical prediction of in-plane permeability for multilayer woven fabrics with manufacture-induced deformation

In this second international permeability benchmark, the in-plane permeability values of a carbon fabric were studied by twelve research groups worldwide. One participant also investigated the deformation of the tested carbon fabric. The aim of this work was to obtain comparable results in order to make a step toward standardization of permeability measurements. Unidirectional injections were thus conducted to determine the unsaturated in-plane permeability tensor of the fabric. Procedures used by participants were specified in the guidelines defined for this benchmark. Participants were asked to use the same values for parameters such as fiber volume fraction, injection pressure and fluid viscosity to minimize sources of scatter. The comparison of the results from each participant was encouraging. The scatter between data obtained while respecting the guidelines was below 25%. However, a higher dispersion was observed when some parameters differed from the recommendations of this exercise. (C) 2014 Elsevier Ltd. All rights reserved.

/pdf/experimental-determination-of-the-permeability-of-3hkcug26ia.pdf

Experimental determination of the permeability of engineering textiles:Benchmark II

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Experimental determination of the permeability of engineering textiles:Benchmark II