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Approach Quantification of manufacturing parameters –Industry-accepted composite manufacturing method: Resin Transfer Mold (RTM), Vacuum Bag Manufacturing modeling using FEA –Fluid flow, including free surface analysis –Heat transfer with autocatalytic reaction kinetics –FEA packages: ANSYS FLOTRAN, ANSYS CFX, COMSOL
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Composite Group ManufacturingMontana State University
Pancasatya “Tiok” Agastra27 November 2012
Impetus• Superior mechanical performance of large
composite structures through energy efficient manufacturing– Substructural details: ply drops, sandwich
construction, ply joints
• Low cost manufacturing and increased turnover rate
• Understanding of resin reaction kinetics
Approach• Quantification of manufacturing parameters
– Industry-accepted composite manufacturing method: Resin Transfer Mold (RTM), Vacuum Bag
• Manufacturing modeling using FEA– Fluid flow, including free surface analysis– Heat transfer with autocatalytic reaction kinetics– FEA packages: ANSYS FLOTRAN, ANSYS CFX,
COMSOL
Governing Equations for Manufacturing Modeling
uk
uuuu ηgρpρηtuρ T
Navier-Stokes Equation with Darcy’s Law
QTCρTtTCρ PP uk
Conduction and Convection
nm21 α1αkk
dtdα
α
0nm
21
t
0 α1αkkdαdt
αΔHHΔ Enthalpy rate of release
Autocatalytic Rate Law
Integral Form of the Rate Law
FLUIDFLOW
HEATTRANSFER
REACTIONKINETICS
Manufacturing MethodsRTM Vacuum Bag
Manufacturing Parameter Quantification & Resin Characterization
Flowrate Temperature
Differential Scanning Calorimetry
Manufacturing Milestone
Blade Root Manufacturing
“Brick” Laminate
Microflow-Scale Modeling• Resin flow in wind turbine blade materials is a complicated local and
global phenomenon (channel flow plus D’Arcy flow in strands)
Baseline Fiber Strand Permeability 6.16E-14 m²
Higher Fiber Strand Permeability 6.16E-12 m²
TRANSVERSE FLOW AXIAL FLOW
Knytex D155 Cross Sectional Area
Heat Transfer Modeling
RTM Vacuum Bag
Fabric Compaction
COMSOL Coupled-FieldThermal-Fluid-Convection
RTM with incoming resin
Large Scale Application
Future Work• Flow properties
– Viscosity and degree of cure correlation– Permeability and compaction
• Chemical and thermal properties– Thermal conductivity– Enthalpy release rates and heating rate