Chung-Hae PARK, Mylène DELEGLISE-LAGARDERE, Patricia KRAWCZAK Mines Douai, TPCIM. Institut Mines-Télécom

Transcription

1 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

2 Importance of performance Evolution of Industrial Applications Penetration into new markets: Cost reduction is a key! Reproducibility & Quality Biomedical Number Aerospace ~20C Military Commercial aircraft Today Quality Mass transport Automotive Construction Tomorrow Importance of cost 2 11/04/2016

3 Final Quality Depends on the Manufacturing! Talyor-made material? Fiber E f G f f f f PROCESS P, T, v, t µ-structure Composite Process control? Trial & error? Predictive tool! V f Eij G ij ij ij ij Matrix E G m m Curing Crystallinity m m m f L f / D f Voids Interface Residual stress 3 11/04/2016

4 Materials & Processes L f /D f Fiber length Injection Compression SRIM LCM Autoclave Thermoforming Prepreg CSM Preform Textile Composites BMC & SMC LFRT SFRT Fiber content V f 4 11/04/2016

5 Liquid Composite Molding Impregnation of continuous dry textile reinforcement by liquid resin Resin Transfer Molding process Resin Injection A320/A340 spoiler Preform Preforming Heating Mold Filling & Curing Releasing Large and complex structures without assembling Reduction of raw material cost and labor Free from volatile trouble Final product 5 11/04/2016

6 Low Cost! Product Quality? Titanium? or Carbon fiber prepreg? Quality?: Defects (porosity, void) Impact resistance (bird strike) Cost Fatigue (high speed rotation) LEAP engine fan blade 3D carbon interlock + Epoxy (Resin Transfer Molding) Low manufacturing cost Enhanced impact resistance Degeneration of mechanical performances Aeronautic standard Void content < 2% 6 11/04/2016

7 Dry zone (short shot) Void Defects in Different Scales Void, Porosity, Air bubble, Dry zone, etc. Race tracking Vent Tow void (inside tow) Intra-bundle void Injection d, small point gap within tows Micropore, Capillary Channel void (between tows) D, large gap between tows Macropore, Viscous Inter-bundle void 1~10m 0.1~1mm 7 11/04/2016

8 Resin Flow Modeling in Different Scales Macroscopic scale Homogeneous porous medium Darcy s law Homogeneous Heterogeneous (d: 1~10 µm, D: 0.1~1mm) Mesoscopic scale Heterogeneous medium: open gap and micro porous zone Stokes-Brinkman equation (viscous flow + capillary flow in porous zone) Fill factor Tow (Darcy s law + Capillary pressure) Open gap (Stokes equation) Pressure 8 11/04/2016

9 Macroscopic Flow Analysis Single-phase analysis Incompressible liquid P=P vent at the flow front Two-phase analysis Incompressible liquid + Compressible air P=P vent at the vent x i Kij r p x j 0 Automotive front SAFRAN hood (half / Nacelle body) x i Kij r p x j 0 p t x x 1Vf p K a ij pa a i a j 9 11/04/2016 Air vent

10 Microvoid Formation Mechanism Mechanical air entrapment at the flow front Competition between the viscous flow between fiber tows and the capillary wicking inside the fiber tow Low resin velocity: Channel void High resin velocity: Tow void 10 11/04/2016

11 Mutli-scale Flow Model: Microvoid Formation Homogeneous medium at the macro-scale Microstructure of fabric Warp K P Double-scale flow 0 l wp, l wt,// y x l =0 l(t) K m l wt, l wp,// Weft l(t) K M t C 11 Macropore Micropore P cap F D 11/04/2016 f K v M P v 1 cos x K m P P ca p : Surface tension : Contact angle dp dx dp dy t C tx, T t C t C t C t y, T t C

12 Vide (%) Microvoid Formation Modeling Unidirectional fabric / constant flow rate injection / in-situ measurement Analytical solution for void content against Ca fnk K, V, D, l,ln M,, Ca* T Fabric micro-architecture f T f T Ca * u cos u : resin velocity 10 8 Macrovides expérimental Microvides expérimental 6 4 Macrovides numérique Microvides numérique 2 Ca opt = ,00E-04 1,00E-03 1,00E-02 Ca 12 11/04/2016

13 Microvoid Formation in Woven Composites Modeling the formation and compression of microvoids Influence of tow orientation! Void content vs. position Void content vs. Ca* Pinj=const Plain weave Ca * u cos u : resin velocity 0.1 0, Warp Weft Channel Total 0,08 Void content Void content 0,06 0, X [m] 11/04/2016 0,02 fnk M, KT, Vf, T, Df, lt,lnca* 0 0,0001 0,0010 0,0100 0,1000 Ca*

14 Microvoid Migration Modeling V air, C t u S V air, C air Microvoid distribution Void migration inside the tow and in the channel Highly bubbly zone (with a constant width) behind the flow front Bleeding! Injection Vents t/t fill =0.003 t/t fill =0.032 t/t fill =0.163 t/t fill =0.476 t/t fill =0.849 t/t fill = /04/2016

15 Performance thermique Themoplastic Matrices Advantages (over thermoset resins) High impact resistance Possibility of patch repair Long (almost unlimited) storage life Disadvantage High viscosity (difficult impregnation) Pa s (TS) vs Pa s (TP) 15 11/04/2016 High performance engineering polymers Engineering polymers Standard polymers ABS PS Amorphe PEI PEEK PES PPS PAR LCP PSU PC MPPO SMA PMMA PVC SAN PI HTN PET TPE PBT NYLON ACETAL PP LDPE HDPE Cristallin Aeronautic Automotive

16 Semi-Products: Polymer-Fiber Pre-Mixture Solid polymer + Reinforcing fiber : Reduce the resin flow path Polymer Powder Polymer Film Polymer Fiber Reinforcement Fiber Commingled yarn Prepreg One-shot manufacturing Polymer Matrix of 3D structure without prepreg Reinforcement Fiber Powder-mixed bundle Thermoforming Film stacking Fiber Fabric 16 FP7 / MAPICC 3D Reinforcement Fiber 11/04/2016 Pre-heating Compression & Cooling Releasing

17 Resin & Air Flow in Micro-Scale PP Glass fiber Thermoconsolidation Heat & Pressure OR P? T? Commingled yarn Micrographic observation Image processing (B/W image) Void content calculation Real textile architecture Resin/air flow modeling (FEM) 17 11/04/2016

18 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 /04/2016