Cure simulation with resistively in situ heated CFRP molds: Implementation and validation

Abstract

In composite processing of parts with varying cross-sections, homogeneous cure is sought but poses a significant challenge. Electrically heated molds for resin transfer molding (RTM) processes offer the potential to locally introduce heat and, thus, achieve more homogeneous cure and enhanced part quality. However, low conductivity of CFRP poses a risk of uncontrolled exothermic reactions. To target this potential, an appropriate and efficient numerical method is presented in this study to simulate part cure governed by resistive heated CFRP molds. A numerical control algorithm for 3D finite element cure simulations is developed, which uses the reaction flux of a temperature boundary condition to calculate the arising tool temperature field. The capability of this method to predict non-uniform tool temperatures of self-heated CFRP molds with close to thermocouple accuracy during the cure process is shown by means of numerical verification and experimental validation on a self-heated CFRP plate.