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

An integrated multi-physics modeling tool will be developed to virtually predict process-induced defects, dimensional change, and performance variations through a coupled infusion-cure modeling framework for low-cost composite parts manufactured via Infusion Molding. This project will leverage the existing high-fidelity infusion and residual stress codes developed by the University of Connecticut (UConn) team. The novel infusion model features two-way Fluid-Structure Interaction (FSI) analysis of the flow compaction response during resin infusion. The high-fidelity residual stress code encompasses resin cure kinetics, cure history-dependent viscoelastic constitutive relations, the micromechanics model, and progressive damage analysis. The CFD-based infusion code and FEA-based residual stress code will be executed using commercial software STAR CCM+ and Abaqus, respectively. The FSI analysis will be realized through the mesh morpher in the CFD solver. The governing equations behind the two codes and the requirements for such connectivity including material characterization and computational methods will be thoroughly examined. Extensive verification and validation will be conducted on predicting actual flow response, residual stress distribution, and the resulting composite strengths and dimensional change. GEM has already secured commitments for technical, verification and validation support from UConn, including characterization of constituent material properties and fabrication of composite parts used in the benchmark examples.