Process Simulation & Optimization for Advanced Tailorable Composites

The proposed innovation is a process simulation workflow for process optimization and part quality prediction of composite parts to enable tailored manufacturing processes. The proposed workflow will map physics-based process simulation of outcomes and defects with the simulation of the effects of the outcomes on part quality. Experimental linking of the two for composites has been performed in research settings, indicating promise and interest in such an integrated tool. The innovation proposed here will not only link process simulation and outcome simulation in a physics-based workflow capable of representing a wide variety of processes, it will develop the uncertainty quantification capability needed to create a robust tool capable of predicting process windows. Phase I will focus developing and validating a methodology and workflow with which to approach this problem for an example defect, proposed to be porosity that will be further developed in Phase II and expanded to other defects. Future project vision involves turning into a software tool and/or integrating capability as a feature in existing software tools like RAVEN or COMPRO for ABAQUS or ANSYS.