Coupled Infusion-Cure Modeling Simulation for Low-Cost Composite Parts for Process Defects and Geometric Conformity

With the increasing use of infusion methods for composite manufacturing, the need to improve part geometric and defect quality while reducing cycle times, cost, and risk is paramount. The use of simulation tools has become a key component in reducing the need for inefficient trial and error experimentation. Historically, flow simulations have been decoupled from cure and residual stress/deformation simulations. In infusion processes, permeability, or ease with which a fluid flows through a porous medium, directly impacts material properties as well as process induced residual stresses and deformations. Specifically, dynamic pressure distribution can cause changes in the fiber volume fraction, affecting both material and mechanical properties. Additionally, these variations in flow and properties can also give rise to other process induced defects such as voids. Therefore, there is a great need for a fully coupled solution for infusion processes. At the end of this Phase I effort, Convergent Manufacturing Technologies-US will have clearly documented and assessed the fundamental science, necessary features and capabilities, as well as define a strategy to couple infusion stress/deformation simulations. The end product envisions a workflow-based integrated COTS tool for pragmatic flow-cure/stress simulations.