Abstract
Residual stresses are generated by tool-part interaction due to the large difference in the coefficients of thermal expansion (CTE) between the tool and the composite part, resulting in more process-induced part deformation. In this paper, a 3-D numerical model considering the influence of tool-part interaction is proposed to predict the deformation in complex-shape composite parts. In this numerical model, the existing path-dependent model is improved to consider the effect of tool-part interaction by adding the residual stress generated by tool-part interaction, and a simplified self-consistent micromechanics model is selected to predict the composite mechanical properties in the viscous and rubbery stages. The predicted and experimental spring-in angles of L- and U-shaped parts are compared. A good agreement shows the validity of the proposed numerical model. A parametric study is performed and the influence of part structural parameters on the spring-in angle is analyzed quantitatively. The results show that the spring-in angles caused by chemical shrinkage and tool-part interaction decrease with the increase of part thickness, but that caused by thermal contraction is almost constant.
Highlights
Benefiting from higher strength and stiffness, advanced fiber-reinforced composites have been widely applied in many areas such as aerospace and ship building
The main objective of this paper is to extend the application of the path-dependent model so that it can consider the influence of tool-part interaction
A 3-D numerical model considering the effect of tool-part interaction is proposed to
Summary
Benefiting from higher strength and stiffness, advanced fiber-reinforced composites have been widely applied in many areas such as aerospace and ship building. Due to thermal anisotropy of composite materials as well as resin chemical shrinkage and tool-part interaction, residual stresses are generated in composite parts during curing [1,2]. After curing, these residual stresses will cause the geometrical deformation of composite parts that are removed from the tool [3,4,5]. It is important to accurately predict the deformation of composite parts so as to improve the assembly quality and reduce the manufacturing cost. Many numerical models have been developed to predict process-induced deformation of composite parts. In order to accurately describe the change of composite mechanical properties during curing, different constitutive models were proposed in numerical models
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