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Characterization of Raw Material Properties for Optimum LCM Processing Chuck Zhang

Characterization of Raw Material Properties for Optimum LCM Processing Chuck Zhang Florida Advanced Center for Composite Technologies (FAC 2 T) Florida A&M University-Florida State University for NSF/DOE/APC Future of Modeling in Composites Molding Processes June 9, 2004.

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Characterization of Raw Material Properties for Optimum LCM Processing Chuck Zhang

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  1. Characterization of Raw Material Properties for Optimum LCM Processing Chuck Zhang Florida Advanced Center for Composite Technologies (FAC2T) Florida A&M University-Florida State University for NSF/DOE/APC Future of Modeling in Composites Molding Processes June 9, 2004

  2. Common Defects in Liquid Composite Molded Parts • Dry spots • Dimension variations • Voids and poor wetting Variations exist in these defects due to the variations in raw materials and processing parameters!

  3. Modeling and Simulation Can Help Predict Flow and Dimension Problems Spring-in by residual stress Flow-induced dryspot Effective process modeling and simulation requires accurate raw material properties!

  4. Research Issues • Statistical characterization of raw materials properties • Stochastic modeling and analysis of process and defects • Robust design to improve process reproducibility

  5. Research Challenges • Accurate estimation of permeability for complex part geometry (modeling) • In-situ measurement of permeability (experimental) • Statistical permeability characterization (modeling & experimental)

  6. upper mold Resin fiber preform Inlet and flowmeter Outlet and flowmeter Lower mold and pressure sensor array Gas N 2 Gas-assisted, Real-time ASsessment of Permeability (GRASP)

  7. Whole-Field Permeability Estimation with GRASP Finite element analysis Fiber preform High permeability Low permeability Computed pressure Flow validation Measured pressure Estimated permeability

  8. N 2 Close Loop LCM Operation with Hardware-In-The-Loop Simulation Preform and mold LCM process In-situ, whole-field permeability measurement (GRASP) GA Hardware-in-the-loop NN Process optimization Flow simulation

  9. Statistical Characterization of Fiber Permeability with GRASP Woven Carbon Fabrics Pressure Distribution Estimated Permeability Standard Dev. = 23.6% of Mean GRASP may be used to validate permeability estimation model

  10. Simulation . . . . . . . . Statistical Characterization of Permeability Experiment Kg1, Kr1 Kg2, Kr2 Racetracking permeability Kgn, Krn

  11. Summary • Variations exist in LCM raw materials and processing parameters and LCM process performance varies due to the variations • Accurate estimation and statistical characterization of permeability are important to improve LCM part quality and process reproducibility

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