Consolidation and Cure Simulations for Laminated Composites

Abstract

Advanced fiber reinforced polymer composites have been increasingly used in various structural components. One of the important processes to fabricate high performance laminated composites is an autoclave assisted prepreg lay-up. Since the quality of laminated composites is largely affected by the cure cycle, selection of the cure cycle for each application is important and must be optimized. Thus, some fundamental model of consolidation and cure processes is necessary to properly select suitable parameters for each application. This article develops a finite element code, which combines ‘the consolidation model’ with ‘the thermo-chemical model’ during the autoclave processing of composite materials. Numerical examples, including comparison of the present numerical results with one-dimensional (1-D) and 2-D analytical solutions, are given to indicate the accuracy and effectiveness of the finite element formulation. In addition, using the finite element code, the 1-D cure process of a laminate made of 52 plies of AS4/3501-6 unidirectional tape is simulated and some numerical results are compared with experimental results available in the literature.

Keywords

processing flow compaction modeling finite element degree of cure

Get full access to this article

View all access options for this article.

References

Hubert, P. and Poursartip, A. (1998) A Review of Flow and Compaction Modeling Relevant to Thermoset Matrix Laminate Processing , J. Reinforced Plastics & Composites, 17: 286-318 .

Hubert, P. , Vaziri, R. and Poursartip, A. (1999). A Two-dimensional Flow Model for the Process Simulation of Complex Shape Composite Laminates , International Journal For Numerical Methods in Engineering, 44: 1-26 .

Loos, A. C. and Springer, G. S. (1983). Curing of Epoxy Matrix Composites , J. Composite Materials, 17: 135-169 .

Gutowski, T. G. , Morigaki, T. and Cai, Z. (1987). The Consolidation of Laminate Composites , J. Composite Materials, 21: 172-188 .

Dave, R. , Kardos, J. L. and Dudukovic, M. P. (1987). A Model for Resin Flow during Composite Processing: Part 1: General Mathematical Development , Polymer Composites, 8(1): 29-38 .

Smith, G. D. and Poursartip, A. (1993). A Comparison of Two Resin Flow Models for Laminate Processing , J. Composite Materials, 27: 1695-1711 .

Dave, R. (1990). A Unified Approach to Modeling Resin Flow during Composite Processing , J. Composite Materials, 24: 22-41 .

Dave, R. , Kardos, J. L. and Dudukovic, M. P. (1987). A Model for Resin Flow during Composite Processing: Part 2: Numerical Analysis for Unidirectional Graphite/Epoxy Laminates , Polymer Composites, 8(2): 123-132 .

Gutowski, T. G. , Morigaki, T. and Cai, Z. (1987). Consolidation Experiments for Laminate Composites , J. Composite Materials, 21: 650-669 .

10.

Young, W. B. (1996). Consolidation and Cure Simulations for Laminated Composites , Polymer Composites, 17(1): 142-148 .

11.

Young, W. B. (1995). Resin Flow Analysis in the Consolidation of Multi-directional Laminated Composites , Polymer Composites, 16(3): 250-257 .

12.

Shin, D. D. and Hahn, H. T. (2004). Compaction of Thick Composites: Simulation and Experiment , Polymer Composites, 25(1): 49-59 .

13.

Hubert, P. and Poursartip, A. (2001). Aspect of the Compaction of Composite Angle Laminates: an Experimental Investigation , J. Composite Materials, 35: 2-26 .

14.

Lewis, R. W. and Schrefler, B. A. (1987). The Finite Element Method in the Deformation and Consolidation of Porous Media, Wiley, Chichester .

15.

Li, X. , Zienkiewicz, O. C. and Xie, M. (1990). A Numerical Model for Immiscible Two-phase Fluid Flow in a Porous Media , International Journal for Numerical Methods in Engineering, 30: 1195-1212 .

16.

Bruschke, M. V. and Advani, S. G. (1990). A Finite Element/Control Volume Approach to Mold Filling in Anisotropic Porous Media , Polymer Composites, 11: 398-405 .

17.

Trochu, F. , Gauvin, R. and Zhang, Z. (1992). Computer Aided Design in Composite Material Technology, Vol. III, Computational Mechanics Publication, Oxford .

18.

ABAQUS (1995). Finite Element Software, ©Hibbitt, Karlsson and Sorensen, Inc.

19.

der Westthuizen, J. V. and Du Plessis, J. P. (1996). An Attempt to Quantify Fiber Bed Permeability Utilizing the Phase Average Navier-Stokes Equation , Composites: Part A, 27A: 263-269 .

20.

der Westthuizen, J. V. and Du Plessis, J. P. (1994). Quantification of Unidirectional Fiber Bed Permeability , J. Composite Materials, 28: 619-637 .

21.

Naji, M. I. and Hoa, S. Y. (2000). Curing of Thick Angle-bend Thermoset Composite Part: Curing Process Modification for Uniform Thickness and Uniform Fiber Volume Fracture Distribution , J. Composite Materials, 34(20): 1710-1755 .

22.

Eckert, E. R. G. and Drake, R. M. (1972). Analysis of Heat and Mass Transfer, McGraw-Hill, New York .

23.

Springer, G. S. and Tsai, S. W. (1967) Thermal Conductivities of Undirectional Materials , J. Composite Materials, 1: 166-166 .

24.

Lee, W. I. , Loos, A. C. and Springer, G. S. (1982). Heat of Reaction, Degree of Cure, and Viscosity of Hercules 3501-6 Resin , J. Composite Materials, 16: 510-520 .

25.

Zienkiewicz, O. C. (1977). The Finite Element Method, McGram-Hill, New York .

26.

Peter, R. C. , Qiuling, Wang and Springer, G. S. (1992). Autoclave Curing - Comparisons of Model and Test Results , J. Composite Materials, 26(1): 90-102 .