Process modelling of composite structures employing a virtual autoclave concept

Abstract

A major obstacle to realizing the full potential of composite structures in commercial applications is cost-effective manufacturing. Achievement of this objective requires development of a more rigorous science-based approach to composites manufacturing than that traditionally employed. This is a realistic goal, as past efforts have demonstrated the potential of process modelling as a tool for development of improved process cycles for simple structures. This paper presents a comprehensive 2-D finite element composite laminate process model which identifies a number of important processing parameters including component internal temperature, resin degree of cure, resin flow and the development of residual stress and deformation. This model advances previous work in a number of ways, allowing modeling of complex 2-D structures with multiple composite and non-composite materials, including the effects of process tooling. A 'virtual autoclave' simulation is used to predict the boundary conditions to which parts are actually subjected during processing.