Technological process optimization of complex shape composite aviation structures autoclave molding with prior correction of their geometry


DOI: 10.34759/trd-2021-116-12

Аuthors

Diukov V. A.

Don State Technical University, DSTU, 1, Gagarin square, Rostov-on-Don, 344003, Russia

e-mail: d-victor-a@mail.ru

Abstract

The article presents geometry correction methods for the complex shape thin-walled composite structures. Topologically correct prepreg and shape-generating rigging models were developed. New prepreg theoretical models obtaining is being ensured by edges sectioning of the original parts by parallel or radial planes and creating surface by the intersection lines of the specified planes and associated facets. For parts creating, the surfaces were being truncated, thickened, and corresponding moulds were being built. The obtained parts and moulds were placed in assemblages.

Thermo-physical parameters of the composite prepreg were assigned to the models, and then the coupled problem of heat transfer and polymerization was being solved. Kinetic equation, which structure and parameters depend on the binder properties, is being employed to describe the dependence of the degree of polymerization on time and temperature. The type and parameters of the kinetic equation are determined from the results of materials analysis by the Differential Scanning Calorimetry (DSC) using various numerical methods for these parameters identification. For the specified technological system, the heat injection method, namely autoclave molding, was selected. The law of temperature variation was selected in the most commonly wide-spread stepwise form: heating – isothermal dwelling – heating – isothermal dwelling – cooling.

As the result, both temperature and time optimalи regimes of the two-stage autoclave molding cycle were selected, which ensure achieving the required degree of polymerization value of the carbon fiber reinforced polymer (CFRP) prepreg, and minimizing temperature differential and binder degree of polymerization in the polymerized volume. Temperature and time regimes of cure affect the structure and quality of the material.

The results of the molding process simulations demonstrated a significant dependence of both the average temperatures and the degree of prepreg polymerization, and their spread in the prepreg and mould, on the characteristics of the technological process and technological limitations.

Keywords:

technological process optimization, autoclave molding, polymer composites, CAD/CAE technologies

References

  1. Bruce F. Kay. Sikorsky S-75 ACAP Helicopter, March 7, 2013, Copyright 2020 Sikorsky Archives. URL: https://www.sikorskyarchives.com/S-75%20ACAP.php

  2. Overcoming the barriers imposed by geometry, CIMdata Report, SpaceClaim Corp., Ann Arbor, MI, USA, 2011, 7 p.

  3. Larionova A.A., Dudchenko A.A., Sergeev V.N. Trudy MAI, 2016, no. 90. URL: http://trudymai.ru/eng/published.php?ID=74691

  4. Turanov R.A., Pykhalov A.A. Trudy MAI, 2019, no. 104. URL: http://trudymai.ru/eng/published.php?ID=102119

  5. Nikolskij A.A. Trudy MAI, 2016, no. 88. URL: http://trudymai.ru/eng/published.php?ID=70417

  6. Shevtsov S., Axenov V., Zhilyaev I., Wu J.K., Snezhina N. FEM model-based optimal control synthesis for curing a large composite structure with CAD imported geometry, MATEC Web of Conferences, 2017, vol. 130, pp. 07001 - 07009. DOI: 10.1051/matecconf/201713007001

  7. Axenov V., Tarasov I., Shevtsov S., Zhilyaev I., Flek M., Snezhina N. Optimal cure control synthesis for FEM model of aircraft composite part with CAD imported geometry, International Conference on Mechanical, System and Control Engineering (ICMSC), 2017. DOI:10.1109/ICMSC.2017.7959432

  8. Slyusar B., Flek M., Goldberg E., Rozhdestvenskaya N., Shevtsov S. Tekhnologiya vertoletostroeniya: Tekhnologiya proizvodstva lopastej vertoletov i aviacionnyh konstrukcij iz polimernyh kompozicionnyh materialov (Helicopter building technology: Technology for of helicopter blades and aircraft structures production from polymer composites), Rostov-na-Donu, Yuzhnyi nauchnyi tsentr RAN, 2013, 230 p.

  9. Smotrova S.A., Naumov S.M., Smotrov A.V. Tekhnologii izgotovleniya silovyh agregatov aviacionnyh konstrukcij iz polimernyh kompozicionnyh materialov (Technologies for aircraft structures power units manufacturing from polymer composite materials), Moscow, Izd-vo Tekhnosfera, 2015, 215 p.

  10. Shevtsov S., Zhilyaev I., Soloviev A., Parinov I., Dubrov V. Optimization of the Composite Cure Process Based on the Thermo-Kinetic Model, Advanced Materials Research, 2012, vol. 569, pp. 185 - 192. DOI: 10.4028/www.scientific.net/AMR.569.185

  11. Chigrinets E.G., Verchenko A.V. Trudy MAI, 2019, no. 104. URL: http://trudymai.ru/eng/published.php?ID=102420

  12. Shevtsov S., Zhilyaev I., Wu J.K., Snezhina N. Model-based multiobjective optimization of cure process control for a large CFRP panel, Engineering Computations, 2018, vol. 35 (2), pp. 1085 - 1097. DOI:10.1108/EC-09-2017-0354

  13. Astapov V.Y., Khoroshko L.L., Afshari P., Khoroshko A.L. Trudy MAI, 2016, no. 87. URL: http://trudymai.ru/eng/published.php?ID=69638

  14. Grischenko S.V. Trudy MAI, 2015, no. 84. URL: http://trudymai.ru/eng/published.php?ID=63011

  15. Slusar B. Mould Heating Distribution Control System Simulation for Polymerization of a Composite Spar for Helicopter Main Rotor Blade, Femlab Conference, Stockholm, Sweden, 2005, pp. 237 - 244.

  16. Jiazhong X. Numerical Simulation Research on Curing Process of Composite Overwrap Considering a Die Model, Journal of reinforced plastics and composites, 2013, vol. 32, pp. 1393 - 1406. DOI: 10.1177/0731684413491328

  17. Um M.K., Daniel I.M., Hwang B.S. A Study of Cure Kinetics by the Use of Dynamic Scanning Calorimetry, Journal of Computer Science and Technology, 2002, vol. 62, pp. 29 - 40. DOI: 10.1016/S0266-3538(01)00188-9

  18. Shevtsov S., Zhaivoronskaia K., Tarasov I. Model Based Control Optimization for Curing the Shell-like Composite Structures in Autoclave Processing, 1st Annual International Conference on Structural Engineering and Mechanics, Athens, Greece, 2016. URL:https://www.researchgate.net/publication/303524919_Model_Based_Control_Optimization_for_Curing_the_Shell-like_Composite_Structures_in_Autoclave_Processing

  19. Liu X.L. et al. Heat transfer analysis and cure modelling of composite repairs for pipelines, Journal of Reinforced Plastics and Composites, 2014, vol. 33, pp. 586 - 597. DOI: 10.1177/0731684413514124

  20. Ding A., Li S., Sun J., Wang J., Zu L. A thermo-viscoelastic model of process-inducedresidual stresses in composite structures with considering thermal dependence, Composite Structures, 2016, vol. 136, pp. 34 - 43. DOI: 10.1016/j.compstruct.2015.09.014


Download

mai.ru — informational site MAI

Copyright © 2000-2024 by MAI

Вход