Material Engineering and Mechanical Manufacturing

Optimized distortion control method of CFRP curing region temperature field driven by near⁃zero stress equivalent temperature field

  • Guanguan CAO ,
  • Ke XU
Expand
  • College of Mechanical and Electrical Engineering,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China

Received date: 2023-10-11

  Revised date: 2023-11-28

  Accepted date: 2023-12-08

  Online published: 2023-12-21

Supported by

National Natural Science Foundation of China(52175466)

Abstract

The cure-induced distortion of Carbon Fiber Resin Matrix Composite (CFRP) components directly affects the mechanical properties and service life of the components after assembly. However, the cure-induced distortion control methods such as tool compensation and structure optimization have the problems of long process cycle time and high cost of iteration. Selective heating methods, such as microwave heating and self-resistive heating, have the potential to realize precise control of the curing temperature field, and generate thermal stresses to hedge the original cure-induced distortion by constructing an uneven temperature field. In this paper, the typical inverse problem of how to construct an inhomogeneous temperature field, a quasi “zero-stress” equivalent temperature field is derived and defined, which in principle can hedge the residual stress field of the component before demolding to achieve a quasi “zero-stress” curing, and thus inhibit the curing deformation after demolding. An adaptive compression partitioning algorithm is designed to partition the theoretical equivalent temperature field with respect to the actual curing temperature process constraints. The method is preliminarily validated on typical hyperbolic and rotary parts, and the results show that compared with isothermal curing, the curing deformation and residual stress are reduced by nearly 50%; compared with the temperature field optimization method that only considers the curing deformation, the curing deformation and residual stress are also reduced by nearly 15%.

Cite this article

Guanguan CAO , Ke XU . Optimized distortion control method of CFRP curing region temperature field driven by near⁃zero stress equivalent temperature field[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2024 , 45(16) : 429703 -429703 . DOI: 10.7527/S1000-6893.2023.29703

References

1 ZHANG C, ZHANG G L, XU J, et al. Review of curing deformation control methods for carbon fiber reinforced resin composites[J]. Polymer Composites202243(6): 3350-3370.
2 WANG B, FAN S J, CHEN J P, et al. A review on prediction and control of curing process-induced deformation of continuous fiber-reinforced thermosetting composite structures[J]. Composites Part A: Applied Science and Manufacturing2023165: 107321.
3 PENG X B, XU J, CHENG Y, et al. The effect of curing deformation on the vibration behavior of laminated composite beams[J]. Composite Structures2021277: 114642.
4 JOOSTEN M W, AGIUS S, HILDITCH T, et al. Effect of residual stress on the matrix fatigue cracking of rapidly cured epoxy/anhydride composites[J]. Composites Part A: Applied Science and Manufacturing2017101: 521-528.
5 WANG H. Effect of spring-in deviation on fatigue life of composite elevator assembly[J]. Applied Composite Materials201825(6): 1357-1367.
6 KAPPEL E. Compensating process-induced distortions of composite structures: A short communication[J]. Composite Structures2018192: 67-71.
7 GALI?SKA A. Compensation of process-induced deformations of double-curved carbon-epoxy composite elements[J]. Polymer Composites201940(9): 3666-3677.
8 LIU Z D, ZHENG X T, FAN W J, et al. An alternative method to reduce process-induced deformation of CFRP by introducing prestresses[J]. Chinese Journal of Aeronautics202235(8): 314-323.
9 WHITE S R, HAHN H T. Cure cycle optimization for the reduction of processing-induced residual stresses in composite materials[J]. Journal of Composite Materials199327(14): 1352-1378.
10 JUNG W K, CHU W S, AHN S H, et al. Measurement and compensation of spring-back of a hybrid composite beam[J]. Journal of Composite Materials200741(7): 851-864.
11 ZHANG W C, XU Y J, HUI X Y, et al. A multi-dwell temperature profile design for the cure of thick CFRP composite laminates[J]. The International Journal of Advanced Manufacturing Technology2021117(3): 1133-1146.
12 KRAVCHENKO O G, KRAVCHENKO S G, PIPES R B. Cure history dependence of residual deformation in a thermosetting laminate[J]. Composites Part A: Applied Science and Manufacturing201799: 186-197.
13 KIM H S, YOO S H, CHANG S H. In situ monitoring of the strain evolution and curing reaction of composite laminates to reduce the thermal residual stress using FBG sensor and dielectrometry[J]. Composites Part B: Engineering201344(1): 446-452.
14 NAWAB Y, BOYARD N, JAQUEMIN F. Effect of pressure and reinforcement type on the volume chemical shrinkage in thermoset resin and composite[J]. Journal of Composite Materials201448(26): 3191-3199.
15 HUI X Y, XU Y J, ZHANG W C, et al. Multiscale collaborative optimization for the thermochemical and thermomechanical cure process during composite manufacture[J]. Composites Science and Technology2022224: 109455.
16 NAWAB Y, TARDIF X, BOYARD N, et al. Determination and modelling of the cure shrinkage of epoxy vinylester resin and associated composites by considering thermal gradients[J]. Composites Science and Technology201273: 81-87.
17 BELLINI C, SORRENTINO L, POLINI W, et al. Spring-in analysis of CFRP thin laminates: Numerical and experimental results[J]. Composite Structures2017173: 17-24.
18 STEFANIAK D, KAPPEL E, SPR?WITZ T, et al. Experimental identification of process parameters inducing warpage of autoclave-processed CFRP parts[J]. Composites Part A: Applied Science and Manufacturing201243(7): 1081-1091.
19 QIAO W, YAO W X. Modelling of process-induced deformation for composite parts considering tool-part interaction[J]. Materials202013(20): E4503.
20 XUE J, WANG W X, TAKAO Y, et al. Reduction of thermal residual stress in carbon fiber aluminum laminates using a thermal expansion clamp[J]. Composites Part A: Applied Science and Manufacturing201142(8): 986-992.
21 GAO H J, ZHANG Y D, WU Q, et al. Fatigue life of 7075-T651 aluminium alloy treated with vibratory stress relief[J]. International Journal of Fatigue2018108: 62-67.
22 MARTíN V, VáZQUEZ J, NAVARRO C, et al. Effect of shot peening residual stresses and surface roughness on fretting fatigue strength of Al7075-T651[J]. Tribology International2020142: 106004.
23 WANG X Q, CHOU K. The effects of stress relieving heat treatment on the microstructure and residual stress of Inconel 718 fabricated by laser metal powder bed fusion additive manufacturing process[J]. Journal of Manufacturing Processes201948: 154-163.
24 LIU K, YE J R, ZHANG B M, et al. Experimental and finite element studies on hot sizing process for L-shaped composite beams[J]. Composites Part A: Applied Science and Manufacturing201687: 161-169.
25 MATSUZAKI R, YOKOYAMA R, KOBARA T, et al. Multi-objective curing optimization of carbon fiber composite materials using data assimilation and localized heating[J]. Composites Part A: Applied Science and Manufacturing2019119: 61-72.
26 LIU S T, LI Y G, GAN J Y, et al. Active control of cure-induced distortion for composite parts using multi-zoned self-resistance electric heating method[J]. Journal of Manufacturing Processes202393: 47-59.
27 XU K, LI Y G, CAO G G, et al. Thermally controlled shape programming via image-based optimization towards distortion-reduced composite curing[J]. Journal of Manufacturing Systems202370: 230-243.
28 丁安心, 李书欣, 倪爱清, 等. 热固性树脂基复合材料固化变形和残余应力数值模拟研究综述[J]. 复合材料学报201734(3): 471-485.
  DING A X, LI S X, NI A Q, et al. A review of numerical simulation of cure-induced distortions and residual stresses in thermoset composites[J]. Acta Materiae Compositae Sinica201734(3): 471-485 (in Chinese).
29 LUO L, ZHANG B M, ZHANG G W, et al. Rapid prediction of cured shape types of composite laminates using a FEM-ANN method[J]. Composite Structures2020238: 111980.
Outlines

/