A preform deformation and resin flow coupled model including the cure kinetics and chemo-rheology for the VARTM process

The present paper deals with preform deformation and resin flow coupled to cure kinetics and chemo-rheology for the VARTM process. By monitoring the coupled resin infusion and curing steps through temperature control, our primary aim is to reduce the cycle time of the process. The analysis is based on the two-phase porous media flow and the preform deformation extended with cure kinetics and heat transfer. A novel feature is the consideration of temperature and preform deformation coupled to resin viscosity and permeability in the VARTM process. To tackle this problem, we extend the porous media framework with the heat transfer and chemical reaction, involving additional convection terms to describe the proper interactions with the resin flow. Shell kinematics is applied to thin-walled preforms, which significantly reduces the problem size. The proposed finite element discretized system of coupled models is solved in a staggered way to handle the partially saturated flow front under non-isothermal conditions efficiently. From the numerical example, we conclude that the cycle time of the VARTM infusion process can be shortened over 68%with the proper temperature control. Moreover, the proposed framework can be applied to optimize the processing parameters and check the compatibility of a resin system for a given infusion task

Elastomer Characterization Method for Trapped Rubber Processing

The increasing high-volume demand for polymer matrix composites (PMCs) brings into focus the need for autoclave alternative processing. Trapped rubber processing (TRP) of PMCs is a method capable of achieving high pressures during polymer matrix composite processing by utilizing thermally induced volume change of a nearly incompressible material inside a closed cavity mold. Recent advances in rubber materials and computational technology have made this processing technique more attractive. Elastomers can be doped with nanoparticles to increase thermal conductivity and this can be further tailored for local variations in thermal conductivity for TRP. In addition, recent advances in computer processing allow for simulation of coupled thermomechanical processes for full part modeling. This study presents a method of experimentally characterizing prospective rubber materials. The experiments are designed to characterize the dynamic in situ change in temperature, the dynamic change in volume, and the resulting real-time change in surface pressure. The material characterization is specifically designed to minimize the number and difficulty of experimental tests while fully capturing the rubber behavior for the TRP scenario. The experimental characterization was developed to provide the necessary data for accurate thermomechanical material models of nearly incompressible elastomeric polymers for use in TRP virtual design and optimization

X-ray tomography based numerical analysis of stress concentrations in non-crimp fabric reinforced composites - assessment of segmentation methods

In this study two automated segmentation methodologies of an X-ray computer tomography based numerical analysis are compared. These are then assessed based on their influence on the stress distribution results of finite element models of glass fibre reinforced composites made out of non-crimp fabrics. Non-crimp fabrics reinforced composites are commonly used for wind turbine blades due to their high stiffness to weight ratio for the dominating bending load. Finite element modelling based on X-ray computer tomography allows the reduction of the cost and can accelerate the development process of the key material parameters of wind turbine blades. Recent research progress in the last years has laid the basis for such a procedure. Those processes must be easy applicable, fast and accurate. The main challenge in current methodologies is the segmentation part. The segmentation methods applied for this study have overcome this issue by being automated. This allows for a comparatively fast transfer from X-ray computer tomographic data to finite element results

A Mechanics Based Surface Image Interpretation Method for Multifunctional Nanocomposites

Graphene nanosheets and thicker graphite nanoplatelets are being used as reinforcement in polymeric materials to improve the material properties or induce new functional properties. By improving dispersion, de-agglomerating the particles, and ensuring the desired orientation of the nano-structures in the matrix, the microstructure can be tailored to obtain specific material properties. A novel surface image assisted modeling framework is proposed to understand functional properties of the graphene enhanced polymer. The effective thermal and mechanical responses are assessed based on computational homogenization. For the mechanical response, the 2-D nanoplatelets are modeled as internal interfaces that store energy for membrane actions. The effective thermal response is obtained similarly, where 2-D nanoplatelets are represented using regions of high conductivity. Using the homogenization simulation, macroscopic stiffness properties and thermal conductivity properties are modeled and then compared to the experimental data. The proposed surface image assisted modeling yields reasonable effective mechanical and thermal properties, where the Kapitza effect plays an important part in effective thermal properties

Macro Scale Independently Homogenized Subcells for Modeling Braided Composites

An analytical method has been developed to analyze the impact response of triaxially braided carbon fiber composites, including the penetration velocity and impact damage patterns. In the analytical model, the triaxial braid architecture is simulated by using four parallel shell elements, each of which is modeled as a laminated composite. Currently, each shell element is considered to be a smeared homogeneous material. The commercial transient dynamic finite element code LS-DYNA is used to conduct the simulations, and a continuum damage mechanics model internal to LS-DYNA is used as the material constitutive model. To determine the stiffness and strength properties required for the constitutive model, a top-down approach for determining the strength properties is merged with a bottom-up approach for determining the stiffness properties. The top-down portion uses global strengths obtained from macro-scale coupon level testing to characterize the material strengths for each subcell. The bottom-up portion uses micro-scale fiber and matrix stiffness properties to characterize the material stiffness for each subcell. Simulations of quasi-static coupon level tests for several representative composites are conducted along with impact simulations

Mechanism based failure of 3D-printed continuous carbon fiber reinforced thermoplastic composites

The present work describes a computational mechanism based failure analysis conducted for 3D-printed continuous carbon fiber reinforced thermoplastic composites (CFRTPCs), which could not be seen in the available literature. The material failure is investigated based on intraply failure evaluation and adopts different failure criteria for the material constituents. The micromechanical modeling employs the Asymptotic Homogenization technique and comprises the selection of a representative volume element statistically equivalent to the microstructure of the material, which is identified from cross-section micrographs. In contrast to recent work, it is demonstrated that an additional relation is required for the macroscopic deviatoric stresses acting over the matrix. This avoids an overestimation of the matrix failure when the reinforced lamina is subjected to longitudinal and shear loads. The resulting failure envelopes are presented and compared to those provided by analytical failure theories available in the literature. The results obtained by the micromechanical approach showed its ability to predict failure of 3D-printed CFRTPCs, in addition to bring different elements for the discussion that could not be captured with analytical models. In this context, it is believed that the characteristics inherent to the microstructure reproduced in the RVE,\ua0 articularly contributed to obtaining more realistic failure envelopes

Modification of a Macromechanical Finite-Element Based Model for Impact Analysis of Triaxially-Braided Composites

A macro level finite element-based model has been developed to simulate the mechanical and impact response of triaxially-braided polymer matrix composites. In the analytical model, the triaxial braid architecture is simulated by using four parallel shell elements, each of which is modeled as a laminated composite. For the current analytical approach, each shell element is considered to be a smeared homogeneous material. The commercial transient dynamic finite element code LS-DYNA is used to conduct the simulations, and a continuum damage mechanics model internal to LS-DYNA is used as the material constitutive model. The constitutive model requires stiffness and strength properties of an equivalent unidirectional composite. Simplified micromechanics methods are used to determine the equivalent stiffness properties, and results from coupon level tests on the braided composite are utilized to back out the required strength properties. Simulations of quasi-static coupon tests of several representative braided composites are conducted to demonstrate the correlation of the model. Impact simulations of a represented braided composites are conducted to demonstrate the capability of the model to predict the penetration velocity and damage patterns obtained experimentally

Expanding Puck and Sch\ufcrmann Inter Fiber Fracture Criterion for Fiber Reinforced Thermoplastic 3D-Printed Composite Materials

The present work expands the application of Puck and Sch\ufcrmann Inter-Fiber Fracture criterion to fiber reinforced thermoplastic 3D-printed composite materials. The effect of the ratio between the transverse compressive strength and the in-plane shear strength is discussed and a new transition point between the fracture conditions under compressive loading is proposed. The recommended values of the inclination parameters, as well as their effects on the proposed method, are also discussed. Failure envelopes are presented for different 3D-printed materials and also for traditional composite materials. The failure envelopes obtained here are compared to those provided by the original Puck and Sch\ufcrmann criterion and to those provided by Gu and Chen. The differences between them are analyzed with the support of geometrical techniques and also statistical tools. It is demonstrated that the Expanded Puck and Sch\ufcrmann is capable of providing more suitable failure envelopes for fiber reinforced thermoplastic 3D-printed composite materials in addition to traditional semi-brittle, brittle and intrinsically brittle composite materials

Robust numerical analysis of fibrous composites from X-ray computed tomography image data enabling low resolutions

X-ray computed tomography scans can provide detailed information about the state of the material after manufacture and in service. X-ray computed tomography aided engineering (XAE) was recently introduced as an automated process to transfer 3D image data to finite element models. The implementation of a structure tensor code for material orientation analysis in combination with a newly developed integration point-wise fibre orientation mapping allows an easy applicable, computationally cheap, fast, and accurate model set-up. The robustness of the proposed approach is demonstrated on a non-crimp fabric glass fibre reinforced composite for a low resolution case with a voxel size of 64 μm corresponding to more than three times the fibre diameter. Even though 99.8% of the original image data is removed, the simulated elastic modulus of the considered non-crimp fabric composite is only underestimated by 4.7% compared to the simulation result based on the original high resolution scan