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www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
ESI’s Composites Simulation Solution
Integrated solution to simulate the manufacturing of
structural composites components
Dr. Xiaoshi Jin
November 2015
2
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
FEA Solution to define and Optimize process parameters
• Dedicated to composites structural components made of continuous fibers
Dedicated to automated processes
• For mass production
• For full control on costs, delays and reproducibility
Address a wide range of materials
• Carbon, Glass and natural fibers
• Thermoplastic and thermoset resins
• Including core, inserts
• Woven fabrics, NCF, UD…
• Prepregs or dry textiles
ESI’s Composites Simulation Solution
What is it?
3
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
PAM-COMPOSITES
ESI’s Composites Simulation Solution
CPD-to-ESI in CATIA V5 XML
Fibersim XML
CATIA-RSO export
CAD / DESIGN
Performance
Analysis
Thermoforming of organosheets
Infusion of a wind blade
Post-cure distortion of a fuselage panel
4
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Copyright © ESI Group, 2015. All rights reserved.
ESI’s Composites Simulation Solution
Fiber orientations
Temperature history
Degree of cure history
Compensated mold (CATIA RSO)
5
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Copyright © ESI Group, 2015. All rights reserved.
PAM-FORM Simulation
What for?
To Simulate
• Preforming
• Draping of thermoset prepregs
• Thermoforming of Organosheet
To Determine and Optimize process parameters such as:
• Kinematic of the tools
• Temperature cycle
• Pressure cycle
• Clamping conditions
• Clamping forces
• Initial flat pattern
Through the prediction of
• Wrinkles
• Thicknesses
• Bridging
• Strains (shearing and in fibers)
• Stresses (Shearing and in fibers)
• Fibers orientation
6
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Copyright © ESI Group, 2015. All rights reserved.
PAM-FORM Simulation
Mechanical deformations
modeling
Non-linear elasto-plastic material with damage
• Possible Temperature, Strain rate and Curvature dependency
• Behavior defined through following input:
• Tension and Compression deformation in fiber directions
• Tension is elastic with damage or plastic (transverse
direction of UD)
• Compression is elastic
• In-plane shear deformation
• Elastic with damage or plastic
• Bending deformation in fiber directions
• Thickness deformation through normal pressure
7
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Copyright © ESI Group, 2015. All rights reserved.
PAM-FORM Simulation
Mechanical deformations
modeling
Material compressibility
• Whether the material is defined as incompressible
• The volume of each element remains constant during the simulation:
epsilon1+epsilon2+epsilon3=0
• Whether the material is defined as compressible
• Thickness is then dependant of the shear deformation and/or pressure
• Possibility to visualize compaction ratio (=initial volume of
element/final volume of element) as an output
8
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Copyright © ESI Group, 2015. All rights reserved.
PAM-FORM Simulation
Mechanical deformations
modeling
Elastic damage behavior
• Damage behavior is automatically activated after each necking point
detected in the stress-strain curves
• Computed damage amount express the broken fiber ratio
• It is approximated as the ratio between the damaged stress amount
and the assumed ideal tensile stress when no damage
9
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Copyright © ESI Group, 2015. All rights reserved.
PAM-FORM Simulation
Thermal modeling
Thermal phenomena coupled to mechanical analysis
• Interesting when thermal dependency in material properties
(prepreg materials)
• The following phenomena can be taken into account:
• Conductivity in the composites material
• Conductivity in the tools
• Heat transfer between composites layers
• Heat transfer between composites and tools
• Convection exchanges
• Radiation exchanges
10
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Copyright © ESI Group, 2015. All rights reserved.
Thermoplastic forming Application
Flap rib thermoforming
Fiber Shearing
Rubber pad forming simulation
Bridging effect
11
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Copyright © ESI Group, 2015. All rights reserved.
Wrinkle
Smooth
surface
Thermoplastic forming Application
Wrinkling prediction
Wrinkling prediction
20 plies carbon UD / APC2-AS4
12
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Initial flat
pattern
Optimized flat
pattern
Poor part
quality Improved part
quality
Simulation setup
Lower tool
Upper tool
4 plies
Thermoplastic forming Application
Flat pattern optimization
Flat pattern optimisation
4 plies / thermoplastic matrix
13
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
0
0,2
0,4
0,6
0,8
1
1,2
t
h
ick
n
es
s
(
m
m
)
webthickness(topsection)
thickness(trial)
web thickness (bottom section)
0
0.2
0.4
0.6
0.8
1
1.2
0 100 200 300 400
chordwise location
thickness
(mm)
thickness (trial)
thickness (PAM-FORM)
480
X=0 X=480
Top section
Bottom section
Laminate thickness
Ultrasonic measurement versus simulation
Thickness per ply
Thermoplastic forming Application
Wing box thermoforming
Process animation
14
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Copyright © ESI Group, 2015. All rights reserved.
Preforming Application
Fiber shearing
15
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
What for?
To Simulate
• RTM
• VARI
• Light RTM
• C-RTM
• Curing
To Determine and Optimize process parameters such as:
• Location of injection gates
• Location of vents
• Position and size of flow media
• Heating of the mold
• Cure cycle
Through the prediction of
• Air traps
• Micro porosity
• Injection time
• Curing time
• Temperature evolution
• Degree of cure evolution
• Pressure in the mold
16
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
Flow in porous media
Darcy’s law
• Darcy’s law: • Resin mass conservation:
Boundary conditions required
to solve the equation:
- imposed pressure
- or imposed flow rate at the inlet
17
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
Thermal phenomena
Temperature of the resin
• Governs the reactivity of the polymerization reaction
• Influences the filling since the viscosity of the resin is temperature
dependent
• Temperature field is governed by following equation:
18
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
Material data
Permeability of the reinforcements
• Permeability is fiber volume content dependent (degree of compaction)
• It also depends on the draping of the reinforcements (fiber “shearing”)
• Fiber volume content and draping results can be computed with PAM-
FORM and imported in PAM-RTM
Viscosity of the resin
• It is temperature and degree of conversion dependent
Kinetics of the resin
• Defined through pre-defined Kamal-Sourour models or User defined
models
19
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
Summary
Coupling of physical phenomena
20
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Copyright © ESI Group, 2015. All rights reserved.
PAM-RTM Simulation
To be released in 2016
Fluid-Mechanics coupling solver
• Includes Navier-Stokes law
• Introduced to treat in a more accurate way processes as
Compression-RTM and Infusion
Vent
Moving Tool
Fixed tool
Mold
Preform
Resin gate
RESIN
INJECTION
Gap
Resin + Preform
Dry Preform
Void
Vent
Moving Tool
Fixed tool
Mold
Preform
TOOL VELOCITY
GAP
Resin + Preform
Dry Preform
Void
Vent
Moving Tool
Fixed tool
Mold
Preform
TOOL VELOCITY
Resin + Preform
Vent
Moving Tool
Fixed tool
Mold
Preform
TOOL
PRESSURE
Resin + Preform
21
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Copyright © ESI Group, 2015. All rights reserved.
30 meters wind spar cap infusion Fan blade of an aircraft engine RTM
Fuselage panel infusion
Infusion Application
Large dimensions parts
Filling time Curing time
Filling degree
22
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Light RTM Application
Bus body side
Optimum resin flow pattern computed
with PAM-RTM
"In this project, the RTM simulation helped us to
secure and to optimize the process. Today, we are
using ESI’s PAM- RTM not only to assess process
parameters, including injection time and pressure
in mold, but also to fine-tune mold design.”
Jérôme RAYNAL
Sales and Export Director
Pôle de Plasturgie de l’Est
• 13*6.5 feet
• fiberglass Chopped Strand Mat (CSM)
• integrated flow media
• Polyester resin
23
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Initial injection points
Secondary injection points/channels
Vents location
Flow front during injection
Infusion Application
Inner liner for hull reinforcement
Very complex part including high shapes (1.2m)
Injection analysis allows determination of injection strategy
(injection points/channels and vents location as well as
open/closing sequence)
to minimize:
Dry spots
Filling and curing times
Fiber washing
Pressure in the mold
24
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Floor pan
injection
TECABS project
Renault – Mines de Douai
RTM Application
Automotive floor panel
25
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Zoom-in on
flow media
influence on
resin flow front
Flow media
Infusion Application
Wind blade
26
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Infusion Application
Aeronautic part
Simulation helped to divide
infusion time by almost 5
while producing better quality
parts with less scraps
(better reproducibility)
27
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Porosity prediction and reduction:
Principle: Critical impregnation velocity:
crit
front v
v



max
RTM Application
Automatic reduction of porosities
28
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Porosity prediction and reduction:
PAM-RTM input data:
0%
2%
4%
6%
8%
10%
12%
14%
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02
Flow velocity (m/sec)
Voids
content
20 psi
30 psi
45 psi
2,5 ml/s
1.26+100.55*(V)
Chomarat - Roviply
12.824-1573.7*(V)
Macro-void
Micro-void
Optimum velocity
Based on experiment
Ca= viscosity*velocity/surface tension/contact angle
Experimental data PAM-RTM input curve
RTM Application
Automatic reduction of porosities
29
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Porosity prediction and reduction:
PAM-RTM output: injection flow rate curve
(a) Constant injection pressure
(b) Constant injection flow rate
(c) Optimized injection flow rate
(a) Constant injection pressure
(b) Constant injection flow rate
(c) Optimized injection flow rate
0
1
2
3
4
5
6
7
0 50 100 150
injection time [sec]
injection
flow
rate
1e-7
[m3/s]
1E-04
1E-03
1E-02
Capillary
number
at
flow
front
RTM Application
Automatic reduction of porosities
30
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
PAM-DISTORTION Simulation
What for?
To simulate
•Process induced distortions such as spring-in and warping
To Define and Optimize parameters such as:
•Stacking definition
•Curing cycle
•Mold material and design
•Mold geometrical compensation
Through the prediction of
•Internal stresses during curing
•Residual stresses after de-molding
•Deformation during curing
•Deformation after de-molding
Takes into account
•Material history during curing process (temperature and degree of cure)
•Thermal and Mechanical interaction with the mold
31
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
PAM-DISTORTION Simulation
Physical phenomena
PAM-DISTORTION computes
• Thermal strains
• Chemical strains
It takes into account resin phase transformation during curing
• Initially the resin is liquid: no stress, no strain
• When the resin reaches gelation (alpha=alpha gel) the resin becomes rubbery.
From this point the resin can sustain stresses.
• When the resin reaches the glass transition temperature (Temperature of the
resin = glass transition temperature) the resin becomes glassy.
• Glass transition temperature evolution is defined using Di Benedetto function.
32
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Copyright © ESI Group, 2015. All rights reserved.
PAM-DISTORTION Simulation
Physical phenomena
Phases of the resin for 1 element during curing
33
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
PAM-DISTORTION simulation
Fuselage Panel
33
Temperature evolution during curing
Degree of cure evolution during curing
Deformed shape / springback
Initial and deformed geometries
34
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
KTM Race Car Application
Front Splitter
Zoom-in on structure
Laminate definition
Fiber: Tenax–J STS 40 F13 24 K 1800 tex; Binding type: plain
Resin+ Hardener: EpikoteResin04695/1 and EpikureCuringAgent 05357
Core: Büfadur67 –15, PUR Foam
Front Splitter
35
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Lower tool
(lock)
Upper
tool
Upper tool’s
displacement
Preforming of upper plies
With PAM-FORM
36
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
wrinkles
Preforming Simulation
To predict and optimize
Thickness distribution
Thinning contour
37
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Copyright © ESI Group, 2015. All rights reserved.
Shear angle
Preforming Simulation
To predict and optimize
Shearing
38
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Export your fiber
orientation for injection
simulation or structural
analysis
Preforming Simulation
To predict and optimize
Fiber orientations
Fiber orientations
39
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Bottom view Top view
Injection Simulation
To predict and optimize
Dry spots & Porosities
3D Injection with PAM-RTM
• Takes into account fiber orientations (impact on permeability) from preforming simulation
40
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Copyright © ESI Group, 2015. All rights reserved.
Bottom view Top view
Injection Simulation
To predict and optimize
Filling time
Filling time
41
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Copyright © ESI Group, 2015. All rights reserved.
Selected Industrial References
42
www.esi-group.com
Copyright © ESI Group, 2015. All rights reserved.
Copyright © ESI Group, 2014. All rights reserved.
THANK YOU
composites@esi-group.com

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PAM-COMPOSITES_IACMI_November2015.pdf

  • 1. 1 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. ESI’s Composites Simulation Solution Integrated solution to simulate the manufacturing of structural composites components Dr. Xiaoshi Jin November 2015
  • 2. 2 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. FEA Solution to define and Optimize process parameters • Dedicated to composites structural components made of continuous fibers Dedicated to automated processes • For mass production • For full control on costs, delays and reproducibility Address a wide range of materials • Carbon, Glass and natural fibers • Thermoplastic and thermoset resins • Including core, inserts • Woven fabrics, NCF, UD… • Prepregs or dry textiles ESI’s Composites Simulation Solution What is it?
  • 3. 3 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-COMPOSITES ESI’s Composites Simulation Solution CPD-to-ESI in CATIA V5 XML Fibersim XML CATIA-RSO export CAD / DESIGN Performance Analysis Thermoforming of organosheets Infusion of a wind blade Post-cure distortion of a fuselage panel
  • 4. 4 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. ESI’s Composites Simulation Solution Fiber orientations Temperature history Degree of cure history Compensated mold (CATIA RSO)
  • 5. 5 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-FORM Simulation What for? To Simulate • Preforming • Draping of thermoset prepregs • Thermoforming of Organosheet To Determine and Optimize process parameters such as: • Kinematic of the tools • Temperature cycle • Pressure cycle • Clamping conditions • Clamping forces • Initial flat pattern Through the prediction of • Wrinkles • Thicknesses • Bridging • Strains (shearing and in fibers) • Stresses (Shearing and in fibers) • Fibers orientation
  • 6. 6 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-FORM Simulation Mechanical deformations modeling Non-linear elasto-plastic material with damage • Possible Temperature, Strain rate and Curvature dependency • Behavior defined through following input: • Tension and Compression deformation in fiber directions • Tension is elastic with damage or plastic (transverse direction of UD) • Compression is elastic • In-plane shear deformation • Elastic with damage or plastic • Bending deformation in fiber directions • Thickness deformation through normal pressure
  • 7. 7 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-FORM Simulation Mechanical deformations modeling Material compressibility • Whether the material is defined as incompressible • The volume of each element remains constant during the simulation: epsilon1+epsilon2+epsilon3=0 • Whether the material is defined as compressible • Thickness is then dependant of the shear deformation and/or pressure • Possibility to visualize compaction ratio (=initial volume of element/final volume of element) as an output
  • 8. 8 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-FORM Simulation Mechanical deformations modeling Elastic damage behavior • Damage behavior is automatically activated after each necking point detected in the stress-strain curves • Computed damage amount express the broken fiber ratio • It is approximated as the ratio between the damaged stress amount and the assumed ideal tensile stress when no damage
  • 9. 9 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-FORM Simulation Thermal modeling Thermal phenomena coupled to mechanical analysis • Interesting when thermal dependency in material properties (prepreg materials) • The following phenomena can be taken into account: • Conductivity in the composites material • Conductivity in the tools • Heat transfer between composites layers • Heat transfer between composites and tools • Convection exchanges • Radiation exchanges
  • 10. 10 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Thermoplastic forming Application Flap rib thermoforming Fiber Shearing Rubber pad forming simulation Bridging effect
  • 11. 11 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Wrinkle Smooth surface Thermoplastic forming Application Wrinkling prediction Wrinkling prediction 20 plies carbon UD / APC2-AS4
  • 12. 12 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Initial flat pattern Optimized flat pattern Poor part quality Improved part quality Simulation setup Lower tool Upper tool 4 plies Thermoplastic forming Application Flat pattern optimization Flat pattern optimisation 4 plies / thermoplastic matrix
  • 13. 13 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. 0 0,2 0,4 0,6 0,8 1 1,2 t h ick n es s ( m m ) webthickness(topsection) thickness(trial) web thickness (bottom section) 0 0.2 0.4 0.6 0.8 1 1.2 0 100 200 300 400 chordwise location thickness (mm) thickness (trial) thickness (PAM-FORM) 480 X=0 X=480 Top section Bottom section Laminate thickness Ultrasonic measurement versus simulation Thickness per ply Thermoplastic forming Application Wing box thermoforming Process animation
  • 14. 14 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Preforming Application Fiber shearing
  • 15. 15 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation What for? To Simulate • RTM • VARI • Light RTM • C-RTM • Curing To Determine and Optimize process parameters such as: • Location of injection gates • Location of vents • Position and size of flow media • Heating of the mold • Cure cycle Through the prediction of • Air traps • Micro porosity • Injection time • Curing time • Temperature evolution • Degree of cure evolution • Pressure in the mold
  • 16. 16 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation Flow in porous media Darcy’s law • Darcy’s law: • Resin mass conservation: Boundary conditions required to solve the equation: - imposed pressure - or imposed flow rate at the inlet
  • 17. 17 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation Thermal phenomena Temperature of the resin • Governs the reactivity of the polymerization reaction • Influences the filling since the viscosity of the resin is temperature dependent • Temperature field is governed by following equation:
  • 18. 18 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation Material data Permeability of the reinforcements • Permeability is fiber volume content dependent (degree of compaction) • It also depends on the draping of the reinforcements (fiber “shearing”) • Fiber volume content and draping results can be computed with PAM- FORM and imported in PAM-RTM Viscosity of the resin • It is temperature and degree of conversion dependent Kinetics of the resin • Defined through pre-defined Kamal-Sourour models or User defined models
  • 19. 19 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation Summary Coupling of physical phenomena
  • 20. 20 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-RTM Simulation To be released in 2016 Fluid-Mechanics coupling solver • Includes Navier-Stokes law • Introduced to treat in a more accurate way processes as Compression-RTM and Infusion Vent Moving Tool Fixed tool Mold Preform Resin gate RESIN INJECTION Gap Resin + Preform Dry Preform Void Vent Moving Tool Fixed tool Mold Preform TOOL VELOCITY GAP Resin + Preform Dry Preform Void Vent Moving Tool Fixed tool Mold Preform TOOL VELOCITY Resin + Preform Vent Moving Tool Fixed tool Mold Preform TOOL PRESSURE Resin + Preform
  • 21. 21 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. 30 meters wind spar cap infusion Fan blade of an aircraft engine RTM Fuselage panel infusion Infusion Application Large dimensions parts Filling time Curing time Filling degree
  • 22. 22 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Light RTM Application Bus body side Optimum resin flow pattern computed with PAM-RTM "In this project, the RTM simulation helped us to secure and to optimize the process. Today, we are using ESI’s PAM- RTM not only to assess process parameters, including injection time and pressure in mold, but also to fine-tune mold design.” Jérôme RAYNAL Sales and Export Director Pôle de Plasturgie de l’Est • 13*6.5 feet • fiberglass Chopped Strand Mat (CSM) • integrated flow media • Polyester resin
  • 23. 23 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Initial injection points Secondary injection points/channels Vents location Flow front during injection Infusion Application Inner liner for hull reinforcement Very complex part including high shapes (1.2m) Injection analysis allows determination of injection strategy (injection points/channels and vents location as well as open/closing sequence) to minimize: Dry spots Filling and curing times Fiber washing Pressure in the mold
  • 24. 24 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Floor pan injection TECABS project Renault – Mines de Douai RTM Application Automotive floor panel
  • 25. 25 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Zoom-in on flow media influence on resin flow front Flow media Infusion Application Wind blade
  • 26. 26 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Infusion Application Aeronautic part Simulation helped to divide infusion time by almost 5 while producing better quality parts with less scraps (better reproducibility)
  • 27. 27 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Porosity prediction and reduction: Principle: Critical impregnation velocity: crit front v v    max RTM Application Automatic reduction of porosities
  • 28. 28 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Porosity prediction and reduction: PAM-RTM input data: 0% 2% 4% 6% 8% 10% 12% 14% 0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02 Flow velocity (m/sec) Voids content 20 psi 30 psi 45 psi 2,5 ml/s 1.26+100.55*(V) Chomarat - Roviply 12.824-1573.7*(V) Macro-void Micro-void Optimum velocity Based on experiment Ca= viscosity*velocity/surface tension/contact angle Experimental data PAM-RTM input curve RTM Application Automatic reduction of porosities
  • 29. 29 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Porosity prediction and reduction: PAM-RTM output: injection flow rate curve (a) Constant injection pressure (b) Constant injection flow rate (c) Optimized injection flow rate (a) Constant injection pressure (b) Constant injection flow rate (c) Optimized injection flow rate 0 1 2 3 4 5 6 7 0 50 100 150 injection time [sec] injection flow rate 1e-7 [m3/s] 1E-04 1E-03 1E-02 Capillary number at flow front RTM Application Automatic reduction of porosities
  • 30. 30 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-DISTORTION Simulation What for? To simulate •Process induced distortions such as spring-in and warping To Define and Optimize parameters such as: •Stacking definition •Curing cycle •Mold material and design •Mold geometrical compensation Through the prediction of •Internal stresses during curing •Residual stresses after de-molding •Deformation during curing •Deformation after de-molding Takes into account •Material history during curing process (temperature and degree of cure) •Thermal and Mechanical interaction with the mold
  • 31. 31 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-DISTORTION Simulation Physical phenomena PAM-DISTORTION computes • Thermal strains • Chemical strains It takes into account resin phase transformation during curing • Initially the resin is liquid: no stress, no strain • When the resin reaches gelation (alpha=alpha gel) the resin becomes rubbery. From this point the resin can sustain stresses. • When the resin reaches the glass transition temperature (Temperature of the resin = glass transition temperature) the resin becomes glassy. • Glass transition temperature evolution is defined using Di Benedetto function.
  • 32. 32 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-DISTORTION Simulation Physical phenomena Phases of the resin for 1 element during curing
  • 33. 33 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. PAM-DISTORTION simulation Fuselage Panel 33 Temperature evolution during curing Degree of cure evolution during curing Deformed shape / springback Initial and deformed geometries
  • 34. 34 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. KTM Race Car Application Front Splitter Zoom-in on structure Laminate definition Fiber: Tenax–J STS 40 F13 24 K 1800 tex; Binding type: plain Resin+ Hardener: EpikoteResin04695/1 and EpikureCuringAgent 05357 Core: Büfadur67 –15, PUR Foam Front Splitter
  • 35. 35 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Lower tool (lock) Upper tool Upper tool’s displacement Preforming of upper plies With PAM-FORM
  • 36. 36 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. wrinkles Preforming Simulation To predict and optimize Thickness distribution Thinning contour
  • 37. 37 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Shear angle Preforming Simulation To predict and optimize Shearing
  • 38. 38 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Export your fiber orientation for injection simulation or structural analysis Preforming Simulation To predict and optimize Fiber orientations Fiber orientations
  • 39. 39 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Bottom view Top view Injection Simulation To predict and optimize Dry spots & Porosities 3D Injection with PAM-RTM • Takes into account fiber orientations (impact on permeability) from preforming simulation
  • 40. 40 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Bottom view Top view Injection Simulation To predict and optimize Filling time Filling time
  • 41. 41 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Selected Industrial References
  • 42. 42 www.esi-group.com Copyright © ESI Group, 2015. All rights reserved. Copyright © ESI Group, 2014. All rights reserved. THANK YOU composites@esi-group.com