Comment la simulation des procédés permet de …images.jeccomposites.com/conference-france-9-fev-2017/... · Institut de Recherche en Génie Civil et Mécanique UMR 6183 CNRS -

Institut de Recherche en Génie Civil et Mécanique UMR 6183 CNRS - École Centrale Nantes - Université de Nantes

Comment la simulation des procédés permet de développer des solutions technologiques grande

cadence ?

C. Binetruy

([email protected])

1

mailto:[email protected]


GeM : C. Binetruy 2

Thèmes de recherche du GeM


GeM : C. Binetruy 3

Thèmes de recherche Comp’Innov

• Mise en oeuvre des matériaux composites• Durabilité, approche fiabilité• Tolérance aux défauts et aux dommages• Comportement et modélisation des

assemblages et structures

Material

ProductProcess

✕


GeM : C. Binetruy

Composite processing for mass production

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• Short cycle time ≈ 1 min• Robust / tolerant / repeatable• Cost-effective• Allows complex design to be manufactured• Need tailored materials and facilities


GeM : C. Binetruy

From aeronautics to automotive applications

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Cutting FormingImpregnation

/ consolidation

Curing / cristallization

Demolding and trimming

Forming

Impregnation / consolidation

Curing / cristallization

Strong coupling

Weak coupling


GeM : C. Binetruy 6

OUTLINE

• Direct manufacturing : example : pultrusion• Virtual material characterization (virtual lab)• Design tailored material• Process robustness• Adapt testing to actual material microstructure

Q : What can numerical simulation be used for?


GeM : C. Binetruy

Direct pultrusion of multi-axial thermoplastic composites

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Flow in consolidating woven fabrics

Polymer injection


GeM : C. Binetruy

Direct pultrusion of multi-axial thermoplastic composites

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Process parameters

Effect on the pressure (P)

Effect on the saturation (S)

Pulling speed U ++ =Viscosity η ++ =Taper angle α ++ ++Taper length ++ ++Die temperature T - +

Criteria P < 10 bar S ≈ 1

Babeau et al, Modeling of heat transfer and unsaturated flow in woven fiber reinforcements during direct injection pultrusion process of thermoplastic composites, Composites Part A, 77, pp.310-318, 2015

Fixed parameters:• Pulling speed = 0,5 m/min

• η = 15 Pa.s

• taper length

Influence of the taper angle on impregnation quality


GeM : C. Binetruy 9

OUTLINE




GeM : C. Binetruy

Material input parameters : 3D permeability tensor

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GeM : C. Binetruy


11


GeM : C. Binetruy


12≈ 450 106 DDL


GeM : C. Binetruy 13

OUTLINE




GeM : C. Binetruy

Design of tailored fabrics with enhanced permeability (ANR Tapas)

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Design parameters• Inter-tow shape and dimensions• 3D connectivity of flow• Scale separation in dual-scale flow

Keep Vf constant to maximize mechanical performance of the final composite

Check the formability by testing and simulations (Lamcos) Yarn compaction at

constant global Vf

Intra-tow

Inter-tow

Intra-tow

H



Design of tailored fabrics with enhanced permeability (ANR Tapas)



OUTLINE





Process robustness : High-Speed RTM with fast curing resin

Deléglise M et al, Modeling of high speed RTM injection with highly reactive resin with on-line mixing. Composites Part A, 2011, 31;42(10):1390-7.



Process robustness

Input : mapped stochastic permeability field

Meshed part Output : stochastic filling time, filling pattern…

Inserts



Process robustness• Scattering in flow patterns and resin arrival time

• Predict the randomness in flow patterns and resin arrival time



OUTLINE





Material characterization : Vf field

Part

thi

ckne

ss

+

Velocity of a longitudinal wave in an isotropic material

E,ρ,ν

LFTPolymer

Velocity measure

E



Material characterization : Coupon size?

ISO 527-4 : 1B coupon

b1 = 10 ± 0.2 mm l1 = 60 ± 0.5 mm

Standard tensile testCorrelation structure of the Vf field

Correlation structure

Correlation length

Guilleminot, J., Soize, C., Kondo, D., & Binetruy, C. (2008). Theoretical framework and experimental procedure for modelling mesoscopic volume fraction stochastic fluctuations in fiber reinforced composites. IJSS, 45(21), 5567-5583.

Vf field (dimensions in cm)

Realizations of Vf

Part 1 . . . . . . . . .

Part 2 . .



Conclusions

• Direct manufacturing : example : pultrusion• Virtual material characterization (virtual lab)• Design tailored material• Process robustness• Adapt testing to actual material microstructure• …




Questions?

Prochaine conférence : 18 Mai 2017, ENS Cachan

Documents

Comment la simulation des procédés permet de …images.jeccomposites.com/conference-france-9-fev-2017/... · Institut de Recherche en Génie Civil et Mécanique UMR 6183 CNRS -