Prediction of Process-Induce Distortions and Residual Stresses of Ancomposite Suspension Blade

Abstract:

This paper deals with a universal simulation strategy for the calculation of process-induceddistortions and residual stresses of a composite part. The mechanical material behavior is describedby a viscoelastic material model depending on temperature and degree of cure . The required materialparameters are derived by dynamic mechanical analyses. For the description of the reaction kinetic aphenomenological based model considering chemical and diffusion-controlled reactions is introduced.The reaction model parameters are fitted to isothermal and dynamic DSC measurements via globaland local optimization. The thermal expansion and chemical shrinkage are characterized by thermalmechanical analysis and using the contact angle measurement method. The simulation strategy isdemonstrated for a GFRP suspension blade for the automobile industry. Based on a sequential coupledtemperature-displacement analysis thermal hot spots, temperature and degree of cure distributions aswell as the final corresponding process-induced distortions and residual stresses are calculated andanalyzed. The development of the stiffness and the correlated stress during the curing process arediscussed in more detail. Furthermore, the effect of a degree of cure dependent stiffness on the stressesis investigated.

• Periodical: Defect and Diffusion Forum (Volume 362)
• Pages: 224-243
• DOI: https://doi.org/10.4028/www.scientific.net/DDF.362.224
• Online since: April 2015
• Authors: Robert Hein, Tobias Wille, Khalil Gabtni, Jean Paul Dias
• Keywords: Curing Kinetic, Exothermal Reactions, Process Simulation, Process-Induced Distortions, Residual Stresses, Viscoelasticity

References

[1] N. Zobeiry: Viscoelastic constitutive models for evaluation of residual stresses in thermoset composites during cure, University of British Columbia, (2006).

[2] G. Fernlund: Spring-in of angled sandwich panels, Compos. Sci. Technol., vol. 65, no. 2, pp.317-323, (2005).

DOI: 10.1016/j.compscitech.2004.08.001

[3] H. T. Hahn and N. J. Pagano : Curing Stresses in Composite Laminates, J. Compos. Mater., vol. 9, no. 1, pp.91-106, (1975).

[4] L. P. Kollar: Approximate Analysis of the Temperature Induced Stresses and Deformations of Composite Shells, J. Compos. Mater., no. 5, pp.392-414 (1994).

[5] D. W. Radford and R. J. Diefendorf: Shape Instabilities in Composites Resulting from Laminate Anisotropy, J. Reinf. Plast. Compos. , vol. 12 , no. 1 , pp.58-75, (1993).

DOI: 10.1177/073168449301200104

[6] K. J. Yoon and J. -S. Kim: Effect of Thermal Deformation and Chemical Shrinkage on the Process Induced Distortion of Carbon/Epoxy Curved Laminates, J. Compos. Mater., vol. 35, no. 3, pp.253-263, (2001).

DOI: 10.1177/002199801772662244

[7] E. Kappel: Process Distortions in Composite Manufacturing - From an Experimental Characterization to a Prediction Approach for the Global Scale, Otto-von-Guericke University Magdeburg, (2013).

[8] A. A. Johnston: An integrated model of the development of process-induced deformation in autoclave processing of composite structures, University of British Columbia (1997), PhD.

[9] G. Fernlund, N. Rahman, R. Courdji, M. Bresslauer, A. Poursartip, K. Willden, and K. Nelson: Experimental and numerical study of the effect of cure cycle, tool surface, geometry, and lay-up on the dimensional fidelity of autoclave-processed composite parts, Compos. Part A Appl. Sci. Manuf., vol. 33, no. 3, pp.341-351, (2002).

DOI: 10.1016/s1359-835x(01)00123-3

[10] G. Fernlund, A. Osooly, A. Poursartip, R. Vaziri, R. Courdji, K. Nelson, P. George, L. Hendrickson, and J. Griffith: Finite element based prediction of process-induced deformation of autoclaved composite structures using 2D process analysis and 3D structural analysis, Compos. Struct., vol. 62, no. 2, pp.223-234 (2003).

DOI: 10.1016/s0263-8223(03)00117-x

[11] T. a. Bogetti and J. W. Gillespie: Process-Induced Stress and Deformation in Thick-Section Thermoset Composite Laminates, J. Compos. Mater., vol. 26, no. 5, pp.626-660, (1992).

DOI: 10.1177/002199839202600502

[12] J. M. Svanberg: Predictions of Manufacturing Induced Shape Distortions - High Perfomance Thermoset Composites, Lulea University of Technology (2002), PhD.

[13] P. Prasatya, G. B. McKenna, and S. L. Simon: A Viscoelastic Model for Predicting Isotropic Residual Stresses in Thermosetting Materials: Effects of Processing Parameters, J. Compos. Mater., vol. 35, no. 10, pp.826-848, (2001).

DOI: 10.1177/002199801772662424

[14] Y. K. Kim and S. R. White: Process-Induced Stress Relaxation Analysis of AS4/3501-6 Laminate, J. Reinf. Plast. Compos., vol. 16, no. 1, pp.2-16 (1997).

DOI: 10.1177/073168449701600102

[15] R. Hein, P. Steinle, T. Wille: Pseudo-Viscoelastic vs. Viscoelasic: Evaluation of Two Material Models for Curing Simulation of CFRP, Conference Proceedings, NAFEMS, Bamberg, Germany (2014).

[16] C. Brauner, Analysis of process-induced distortions and residual stresses of composite structures, Faserinstitut Bremen (2013), PhD.

[17] M. V. Zocher: A thermoviscoelastic finite element formulation for the analysis of composites, Texas A& M University (1995), PhD.

[18] H. Poon and M. F. Ahmad: A material point time integration procedure for anisotropic, thermo rheologically simple, viscoelastic solids, Comput. Mech., vol. 21, no. 3, pp.236-242 (1998).

DOI: 10.1007/s004660050298

[19] L. K. Jain and Y. -W. Mai: Stresses and Deformations Induced during Manufacturing. Part I: Theoretical Analysis of Composite Cylinders and Shells, J. Compos. Mater., vol. 31, no. 7, pp.672-695, (1997).

DOI: 10.1177/002199839703100703

[20] H. W. Wiersma, L. J. B. Peeters, and R. Akkerman: Prediction of springforward in continuousfibre/polymer L-shaped parts, Compos. Part A Appl. Sci. Manuf., vol. 29, no. 11, pp.1333-1342, (1998).

DOI: 10.1016/s1359-835x(98)00062-1

[21] N. I. Karkanas and I. K. Partridge: Cure Modeling and Monitoring of Epoxy/Amine Resin Systems. I. Cure Kinetics Modeling, J. Appl. Polym. Sci., vol. 77, no. 7, pp.1419-1431. (2000).

DOI: 10.1002/1097-4628(20000815)77:7<1419::aid-app3>3.0.co;2-n

[22] S. Freund: Entwicklung eines Programms zur robusten Bestimmung der reaktionskinetischen Modellparameter für die Aushärtesimulation von Epoxidharzen., German Aerospace Center (DLR), Internal Report (2010).

[23] J. P. Pascault and R. J. J. Williams: Glass Transition Temperature Versus Conversion Relationships For Thermosetting Polymers, vol. 28, p.8595 (1990).

[24] J. D. Ferry: Viscoelastic Properties of Polymers, 2nd Edition, New York: John Wiley & Sons (1980).

[25] G. C. Papanicolaou and S. P. Zaoutsos: Viscoelastic constitutive modeling of creep and stress relaxation in polymers and polymer matrix composites, Woodhead Publishing Series in Composites Science and Engineering, R. M. B. T. -C. and F. in P. M. C. Guedes, Ed. Woodhead Publishing, p.347, (2011).

DOI: 10.1533/9780857090430.1.3

[26] D. Kroshko: OpenOpt, [Online], Available: http: /openopt. org.

[27] International Standard: Plastics-Differnetial Scanning calorimetriy (DSC), Part 2: Determination of glass transition temperature (1999).

[28] M. Herdy: ViscoData & ViscoShift, Avaiable: http: /www. viscodata. de, (2003).

[29] C. C. Chamis: Simplified composite micromechanics equations for hygral, thermal and mechanical properties, SAMP Q., vol. NASA-TM-83, COMPOSITE MATERIALS, p.19 (1987).

[30] Hutchinson S. A.: http: /www. hutchinsonworldwide. com.

[31] H. Schürmann: Konstruieren mit Faser-Kunststoff-Verbunden, Berlin/Heidelberg, SpringerVerlag (2005).

DOI: 10.1007/b137636

[32] R. F. GmbH: R& G Handbook Composite Materials, http: /www. r-g. de (2014).

[33] A. S. Ulrich Fischer, Roland Gomeringer, Max Heinzler, Roland Kilgus, Friedrich Näher, Stefan Oesterle, Heinz Paetzold: Tabellenbuch Metall mit Formelsammlung, Europa-Lehrmittel (2011).

[34] V. Kaushik and J. Raghavan: Experimental study of tool-part interaction during autoclave processing of thermoset polymer composite structures, Compos. Part A Appl. Sci. Manuf., vol. 41, no. 9, pp.1210-1218, (2010).

DOI: 10.1016/j.compositesa.2010.05.003