Institut Mines-Télécom

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

Institut Mines-Télécom

Evolution of Industrial Applications

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 2

Construction

Automotive

Mass transport

Commercial aircraft

Military

Aerospace

Biomedical

Importance of cost

Imp

ort

an

ce o

f p

erfo

rma

nce

~20C

Tomorrow

Today

Penetration into new markets: Cost reduction is a key!

Quality

Number

Reproducibility & Quality

Institut Mines-Télécom

Final Quality Depends on the Manufacturing !

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 3

fV

f

Fiber

Matrix

µ-structure fffff GE

mmmmm GE

ijijijijij GE

ff DL /

Composite

PROCESS

P, T, v, t

Voids

Interface

Residual stress

Curing

Crystallinity

Talyor-made material? Process control?

Trial & error?

Predictive tool!

Institut Mines-Télécom

Materials & Processes

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 4

Lf /Df

Vf

Injection Compression SRIM

SFRT

LFRT

BMC & SMC

CSM

Preform

LCM Autoclave

Thermoforming

Prepreg

Textile Composites

Fiber content

Fiber

length

Institut Mines-Télécom

Liquid Composite Molding

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 5

Resin Injection

Preforming Mold Filling

& Curing

Releasing Heating

Resin Transfer Molding process

Large and complex structures without assembling

Reduction of raw material cost and labor

Free from volatile trouble

Impregnation of continuous dry textile reinforcement by liquid resin

Preform

Final product

A320/A340 spoiler

Institut Mines-Télécom

Low Cost ! Product Quality ?

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 6

Quality?: Defects (porosity, void)

Degeneration of

mechanical

performances

Aeronautic standard

Void content < 2%

LEAP engine

fan blade

3D carbon interlock +

Epoxy

(Resin Transfer Molding)

Impact resistance (bird strike)

Fatigue (high speed rotation)

Titanium?

or

Carbon fiber

prepreg?

Cost

Low manufacturing cost

Enhanced impact resistance

Institut Mines-Télécom

Void Defects in Different Scales

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 7

Dry zone (short shot)

Race tracking

Injection

point Vent

Channel void (between tows) Tow void (inside tow)

0.1~1mm 1~10m

Void, Porosity, Air bubble, Dry zone, etc.

Inter-bundle void

Intra-bundle void

d, small

gap

within tows

D, large gap

between tows

Macropore, Viscous

Micropore, Capillary

Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM

Resin Flow Modeling in Different Scales

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Macroscopic scale

Homogeneous porous medium

Darcy’s law

Mesoscopic scale

Heterogeneous medium: open gap and micro porous zone

Stokes-Brinkman equation (viscous flow + capillary flow in porous zone) Fill factor

Pressure Tow (Darcy’s law + Capillary pressure) Open gap (Stokes equation)

Homogeneous Heterogeneous (d: 1~10 µm, D: 0.1~1mm)

Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM

Macroscopic Flow Analysis

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Single-phase analysis

Incompressible liquid

P=Pvent at the flow front

0

jr

ij

i x

pK

x

Incompressible liquid + Compressible air

P=Pvent at the vent

Two-phase analysis

1 f ija a

a i a j

V Kp p

p t x x

0

jr

ij

i x

pK

x

Automotive front

hood (half body)

Air vent

SAFRAN / Nacelle

Institut Mines-Télécom

Microvoid Formation Mechanism

11/04/2016 Chung-Hae PARK, Mines Douai / TPCIM 10

Mechanical air entrapment at the flow front

Competition between the viscous flow between fiber tows and the capillary

wicking inside the fiber tow

High resin velocity: Tow void Low resin velocity: Channel void

Institut Mines-Télécom

Mutli-scale Flow Model: Microvoid Formation

11/04/2016

Chung-Hae PARK, Mines Douai / TPCIM

11

Homogeneous medium at the macro-scale

0

P

K

Warp

Weft

x

y

//,wtl

,wpl

//,wpl,wtl

Microstructure of fabric

Double-scale flow

x

KM

l =0 l(t)

Km

l(t)

Pv M

K

ca pm PPv

KMicropore

Macropore

cos

1

f

capD

FP

: Surface tension

: Contact angle

dx

dP

dy

dP

Ct

CTx tt ,Ct

Ct

CTy tt ,Ct

Institut Mines-Télécom

Microvoid Formation Modeling

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Unidirectional fabric / constant flow rate injection / in-situ measurement

Analytical solution for void content against Ca

0

2

4

6

8

10

12

14

1,00E-04 1,00E-03 1,00E-02

Vid

e (

%)

Ca

Macrovidesexpérimental

Microvidesexpérimental

Macrovidesnumérique

Microvidesnumérique

Caopt=1.3910-3

*ln,,,,, , CalDVKKfn TfTfTM

Fabric micro-architecture *

cos

: resin velocity

uCa

u

Chung-Hae PARK, Mines Douai / TPCIM

Institut Mines-Télécom

Microvoid Formation in Woven Composites

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0

0.02

0.04

0.06

0.08

0.1

0 0.2 0.4 0.6 0.8 1

X [m]

Vo

id c

on

ten

t

Warp

Weft

Channel

Total

0

0,02

0,04

0,06

0,08

0,1

0,0001 0,0010 0,0100 0,1000

Ca*

Vo

id c

on

ten

t

Void content vs. position Void content vs. Ca* *

cos

: resin velocity

uCa

u

Modeling the formation and compression of microvoids

Influence of tow orientation!

Pinj=const

Plain weave

*ln,,,,, , CalDVKKfn TfTfTM

Chung-Hae PARK, Mines Douai / TPCIM

Institut Mines-Télécom

Microvoid Migration Modeling

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Microvoid distribution

Void migration inside the tow and in the channel

t/tfill=0.003 t/tfill=0.032 t/tfill=0.163

t/tfill=0.476 t/tfill=0.849 t/tfill=0.999

Injection

Vents

Bleeding !

SuVt

VairCair

Cair

,

,

Chung-Hae PARK, Mines Douai / TPCIM

Highly bubbly zone (with a constant width) behind the flow front

Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM

Themoplastic Matrices

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Advantages (over thermoset resins)

High impact resistance

Possibility of patch repair

Long (almost unlimited) storage life

High performance

engineering polymers

Engineering polymers

Standard

polymers

Amorphe Cristallin

Pe

rfo

rma

nc

e t

he

rmiq

ue

PES PEI

PSU PAR

PEEK

PC

MPPO

SMA ABS PMMA

PS SAN PVC

PP LDPE

HDPE

PPS

PI

PET PBT

NYLON ACETAL

LCP HTN

TPE

Disadvantage

High viscosity (difficult impregnation)

0.1-1 Pa s (TS) vs. 102 – 105 Pa s (TP)

Aeronautic

Automotive

Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM

Semi-Products: Polymer-Fiber Pre-Mixture

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Solid polymer + Reinforcing fiber : Reduce the resin flow path

Fiber Fabric

Polymer Film Polymer Fiber

Reinforcement Fiber

Commingled yarn Film stacking

Polymer Powder

Reinforcement Fiber

Powder-mixed bundle

Prepreg Thermoforming

Reinforcement Fiber

Polymer Matrix

Pre-heating Releasing Compression & Cooling

One-shot manufacturing

of 3D structure

without prepreg

FP7 / MAPICC 3D

Institut Mines-Télécom Chung-Hae PARK, Mines Douai / TPCIM

Resin & Air Flow in Micro-Scale

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Thermo-

consolidation

Heat & Pressure Glass

fiber

PP OR

P?

T?

Micrographic observation

Image processing (B/W

image)

Void content calculation Real textile architecture

Resin/air flow modeling (FEM)

Commingled yarn

Institut Mines-Télécom

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.

11/04/2016 18 Chung-Hae PARK, Mines Douai / TPCIM