Virtual manufacturing of composite aerostructures

Abstract

ABSTRACTThe past century has witnessed the rise and maturity of the flying machine, starting with the Wright brothers flyer to today’s modern passenger aircrafts and warfighters. At the start of this century, yet another achievement in flying vehicle technology was seen with the launch of the Boeing 787 aircraft, which has a significant portion by weight of polymer matrix fibre composites. This paper, therefore, addresses the effects of the manufacturing process of fibre reinforced polymer matrix composites on mechanical performance. Computations are carried out using the Finite Element (FE) method at the microscale where Representative Volume Elements (RVEs) are analysed with Periodic Boundary Conditions (PBCs). Straight fibre pre-preg-based composites and textile composites are considered. The commercial code ABAQUS is used as the solver for the FE equations, supplemented by user-written subroutines. The transition from a continuum to damage/failure is effected by using the Bažant-Oh crack band model, which preserves mesh objectivity. Results are presented for RVEs that are first subjected to curing and subsequently to mechanical loading. The effect of the fibre packing randomness on the microstructure is examined by considering multifibre RVEs where fibre volume fraction is held constant but with random packing of fibres. Plain weave textile composites are also cured first and then subjected to mechanical loads. The possibility of failure is accommodated throughout the analysis – failure can take place during the curing process even prior to the application of in-service mechanical loads. The analysis shows the differences in both the cured RVE strength and stiffness, when cure-induced damage has and has not been taken into account.