modélisation et simulation de la fabrication des matériaux ... · 1,00e-04 1,00e-03 1,00e-02) ca...
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Institut Mines-Télécom
Modélisation et Simulation de la
Fabrication des Matériaux Composites à
Matrices Thermodurcissable ou
Thermoplastique en Conditions Sévères
de Mise en Œuvre et Mise en Forme
Chung-Hae PARK, Mylène DELEGLISE-LAGARDERE, Patricia KRAWCZAK
Mines Douai, TPCIM
Institut Mines-Télécom
Evolution of Industrial Applications
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 2
Construction
Automotive
Mass transport
Commercial aircraft
Military
Aerospace
Biomedical
Importance of cost
Imp
ort
an
ce o
f p
erfo
rma
nce
~20C
Tomorrow
Today
Penetration into new markets: Cost reduction is a key!
Quality
Number
Reproducibility & Quality
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Final Quality Depends on the Manufacturing !
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 3
fV
f
Fiber
Matrix
µ-structure fffff GE
mmmmm GE
ijijijijij GE
ff DL /
Composite
PROCESS
P, T, v, t
Voids
Interface
Residual stress
Curing
Crystallinity
Talyor-made material? Process control?
Trial & error?
Predictive tool!
Institut Mines-Télécom
Materials & Processes
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 4
Lf /Df
Vf
Injection Compression SRIM
SFRT
LFRT
BMC & SMC
CSM
Preform
LCM Autoclave
Thermoforming
Prepreg
Textile Composites
Fiber content
Fiber
length
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Liquid Composite Molding
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 5
Resin Injection
Preforming Mold Filling
& Curing
Releasing Heating
Resin Transfer Molding process
Large and complex structures without assembling
Reduction of raw material cost and labor
Free from volatile trouble
Impregnation of continuous dry textile reinforcement by liquid resin
Preform
Final product
A320/A340 spoiler
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Low Cost ! Product Quality ?
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 6
Quality?: Defects (porosity, void)
Degeneration of
mechanical
performances
Aeronautic standard
Void content < 2%
LEAP engine
fan blade
3D carbon interlock +
Epoxy
(Resin Transfer Molding)
Impact resistance (bird strike)
Fatigue (high speed rotation)
Titanium?
or
Carbon fiber
prepreg?
Cost
Low manufacturing cost
Enhanced impact resistance
Institut Mines-Télécom
Void Defects in Different Scales
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 7
Dry zone (short shot)
Race tracking
Injection
point Vent
Channel void (between tows) Tow void (inside tow)
0.1~1mm 1~10m
Void, Porosity, Air bubble, Dry zone, etc.
Inter-bundle void
Intra-bundle void
d, small
gap
within tows
D, large gap
between tows
Macropore, Viscous
Micropore, Capillary
Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM
Resin Flow Modeling in Different Scales
11/04/2016 8
Macroscopic scale
Homogeneous porous medium
Darcy’s law
Mesoscopic scale
Heterogeneous medium: open gap and micro porous zone
Stokes-Brinkman equation (viscous flow + capillary flow in porous zone) Fill factor
Pressure Tow (Darcy’s law + Capillary pressure) Open gap (Stokes equation)
Homogeneous Heterogeneous (d: 1~10 µm, D: 0.1~1mm)
Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM
Macroscopic Flow Analysis
11/04/2016 9
Single-phase analysis
Incompressible liquid
P=Pvent at the flow front
0
jr
ij
i x
pK
x
Incompressible liquid + Compressible air
P=Pvent at the vent
Two-phase analysis
1 f ija a
a i a j
V Kp p
p t x x
0
jr
ij
i x
pK
x
Automotive front
hood (half body)
Air vent
SAFRAN / Nacelle
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Microvoid Formation Mechanism
11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 10
Mechanical air entrapment at the flow front
Competition between the viscous flow between fiber tows and the capillary
wicking inside the fiber tow
High resin velocity: Tow void Low resin velocity: Channel void
Institut Mines-Télécom
Mutli-scale Flow Model: Microvoid Formation
11/04/2016
Chung-Hae PARK, Mines Douai / TPCIM
11
Homogeneous medium at the macro-scale
0
P
K
Warp
Weft
x
y
//,wtl
,wpl
//,wpl,wtl
Microstructure of fabric
Double-scale flow
x
KM
l =0 l(t)
Km
l(t)
Pv M
K
ca pm PPv
KMicropore
Macropore
cos
1
f
capD
FP
: Surface tension
: Contact angle
dx
dP
dy
dP
Ct
CTx tt ,Ct
Ct
CTy tt ,Ct
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Microvoid Formation Modeling
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Unidirectional fabric / constant flow rate injection / in-situ measurement
Analytical solution for void content against Ca
0
2
4
6
8
10
12
14
1,00E-04 1,00E-03 1,00E-02
Vid
e (
%)
Ca
Macrovidesexpérimental
Microvidesexpérimental
Macrovidesnumérique
Microvidesnumérique
Caopt=1.3910-3
*ln,,,,, , CalDVKKfn TfTfTM
Fabric micro-architecture *
cos
: resin velocity
uCa
u
Chung-Hae PARK, Mines Douai / TPCIM
Institut Mines-Télécom
Microvoid Formation in Woven Composites
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0
0.02
0.04
0.06
0.08
0.1
0 0.2 0.4 0.6 0.8 1
X [m]
Vo
id c
on
ten
t
Warp
Weft
Channel
Total
0
0,02
0,04
0,06
0,08
0,1
0,0001 0,0010 0,0100 0,1000
Ca*
Vo
id c
on
ten
t
Void content vs. position Void content vs. Ca* *
cos
: resin velocity
uCa
u
Modeling the formation and compression of microvoids
Influence of tow orientation!
Pinj=const
Plain weave
*ln,,,,, , CalDVKKfn TfTfTM
Chung-Hae PARK, Mines Douai / TPCIM
Institut Mines-Télécom
Microvoid Migration Modeling
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Microvoid distribution
Void migration inside the tow and in the channel
t/tfill=0.003 t/tfill=0.032 t/tfill=0.163
t/tfill=0.476 t/tfill=0.849 t/tfill=0.999
Injection
Vents
Bleeding !
SuVt
VairCair
Cair
,
,
Chung-Hae PARK, Mines Douai / TPCIM
Highly bubbly zone (with a constant width) behind the flow front
Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM
Themoplastic Matrices
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Advantages (over thermoset resins)
High impact resistance
Possibility of patch repair
Long (almost unlimited) storage life
High performance
engineering polymers
Engineering polymers
Standard
polymers
Amorphe Cristallin
Pe
rfo
rma
nc
e t
he
rmiq
ue
PES PEI
PSU PAR
PEEK
PC
MPPO
SMA ABS PMMA
PS SAN PVC
PP LDPE
HDPE
PPS
PI
PET PBT
NYLON ACETAL
LCP HTN
TPE
Disadvantage
High viscosity (difficult impregnation)
0.1-1 Pa s (TS) vs. 102 – 105 Pa s (TP)
Aeronautic
Automotive
Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM
Semi-Products: Polymer-Fiber Pre-Mixture
11/04/2016 16
Solid polymer + Reinforcing fiber : Reduce the resin flow path
Fiber Fabric
Polymer Film Polymer Fiber
Reinforcement Fiber
Commingled yarn Film stacking
Polymer Powder
Reinforcement Fiber
Powder-mixed bundle
Prepreg Thermoforming
Reinforcement Fiber
Polymer Matrix
Pre-heating Releasing Compression & Cooling
One-shot manufacturing
of 3D structure
without prepreg
FP7 / MAPICC 3D
Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM
Resin & Air Flow in Micro-Scale
11/04/2016 17
Thermo-
consolidation
Heat & Pressure Glass
fiber
PP OR
P?
T?
Micrographic observation
Image processing (B/W
image)
Void content calculation Real textile architecture
Resin/air flow modeling (FEM)
Commingled yarn
Institut Mines-Télécom
Conclusions
Low cost manufacturing techniques for structural
composites are widely employed for aeronautic and
automotive applications.
The final product quality depends on the manufacturing
technology.
The simulation tools to predict process-induced defects
are indispensable.
The influence from the manufacturing process on the
mechanical properties of final products should be
considered in the structural design.
Multi-scale and multi-physics approaches should be
adopted in the composites manufacturing process
modeling.
11/04/2016 18 Chung-Hae PARK, Mines Douai / TPCIM