PAM-FORM 2G 2013 - Feiplar Composites & Feipur · Title: Product presentation Author:...
Transcript of PAM-FORM 2G 2013 - Feiplar Composites & Feipur · Title: Product presentation Author:...
Copyright © ESI Group, 2012. All rights reserved. Copyright © ESI Group, 2012. All rights reserved.
PAM-FORM 2G 2013 Thermoforming of dry textiles and prepregs
July 23rd, 2013
Mathilde Chabin
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Copyright © ESI Group, 2012. All rights reserved.
Introduction to ESI Composites Manufacturing Suite
PAM-FORM 2G product presentation
References
CONTENT
2
Copyright © ESI Group, 2012. All rights reserved.
Introduction to ESI Composites Manufacturing Suite
PAM-FORM 2G product presentation
References
CONTENT
3
Copyright © ESI Group, 2012. All rights reserved.
ESI Composites Manufacturing Suite
4
(1) Standalone version or CATIA V5 embedded
Note: ESI solution can use draping results from non-ESI applications as Fibersim, Composites Design by DS… ESI chain
Courtesy: AAR, Cranfield University, EADS/M, ENISE
FORMING PAM-QUIKFORM(1)
PAM-FORM2G
PREFORM PAM-QUIKFORM(1)
PAM-FORM2G
LCM PAM-RTM(1)
DISTORTION PAM-DISTORTION
CURING
In Autoclave CFD-ACE
Out-Of-Autoclave PAM-RTM
Copyright © ESI Group, 2012. All rights reserved.
Introduction to ESI Composites Manufacturing Suite
PAM-FORM 2G product presentation
What is new in 2013 version
References
CONTENT
5
Copyright © ESI Group, 2012. All rights reserved.
PAM-FORM 2G
Process Schematic
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SOFTEN PLIES PLACE IN TOOLS FORM EJECT PREFORM
PLACE IN TOOLS
HEAT PLIES
FORM
PLACE IN TOOLS FORM
COMPRESSION
EJECT PREFORM
LIQUID
COMPOSITE
MOLDING
CURE IN AUTOCLAVE CURE IN TOOLS OR
PAM-RTM / PAM-DISTORTION PAM-FORM
TE
XT
ILE
PR
EF
OR
MIN
G
TH
ER
MO
SE
T
FO
RM
ING
TH
ER
MO
PL
AS
TIC
FO
RM
ING
CRISTALLISATION
Copyright © ESI Group, 2012. All rights reserved.
PAM-FORM 2G simulation
What for?
To define and optimize:
Forming strategy: stamping, thermoforming, diaphragm forming…
Process parameters: tool velocity, holding system and force,
temperature cycle, pressure cycle, material type and thickness for
diaphragms…
Through the prediction of:
Wrinkling
Bridging
Thickness
Optimum flat pattern
Final fiber orientation
With material models for NCF, UD and woven fabrics
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Automotive B-Pillar
Copyright © ESI Group, 2012. All rights reserved.
PAM-FORM 2G simulation
Material data requirements
Material data are needed for each ply of the laminate
Data should cover temperature range of the process
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DEFORMATION MODE REPRESENTATION SIMULATION INPUT COMMENTS
Fiber extension Young’s modulus
(E1, E2)
To be done for both fiber
directions
Fiber buckling Young’s modulus = f(strain)
(E1, E2)
To be done for both fiber
directions
In-plane shear Force/Displacement
(G)
To be done for positive and
negative shear
Bending
Simulations for Bending
Stiffness calibration
(B1, B2)
To be done for both fiber
directions
Compaction Thickness = f(pressure) Can be done for different
shear angles
Sliding Friction coefficient
Can be temperature, velocity
and pressure dependent
To be done between plies
and between plies and tools
In-plane shear viscosity Viscosity Can be temperature
dependent
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UD thermoforming: 20 plies of carbon unidirectional
thermoplastic matrix –APC2-AS4
Courtesy: Dassault Aviation
PAM-FORM2G simulation
Top and Bottom ply (End view)
Top
View
Bottom
View
Wrinkle
Smooth
surface
PAM-FORM 2G simulation
Example 1: Wrinkling prediction
Copyright © ESI Group, 2012. All rights reserved.
PEI-CETEX; 8 plies
Woven fabrics thermoforming: impact of punch
velocity
PUNCH VELOCITY= 5.mm/s PUNCH VELOCITY=40.mm/s
Courtesy: Dassault Aviation
PAM-FORM 2G simulation
Example 2: Process definition
Copyright © ESI Group, 2012. All rights reserved.
+ - 45 0/90 Clamping system definition
Laminate definition
Courtesy: Dassault Aviation
PAM-FORM 2G simulation
Example 3: Material definition
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PAM-FORM 2G simulation
Example 4: Shearing prediction
on preform
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Courtesy: Delft University of Technology
Fabric / 6 plies / PPS Matrix
PAM-FORM2G simulation
Highlights on bridging risks
PAM-FORM 2G simulation
Example 5: Bridging prediction
Copyright © ESI Group, 2012. All rights reserved.
Introduction to ESI Composites Manufacturing Suite
PAM-FORM 2G product presentation
References
CONTENT
14
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AUDI
Lamborghini
Bilcare
BMW
DLR
DOW
EUROCOPTER
Some References
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GE
Mercedes-Benz
Letov
Minoru Kasai
NCC
VW
Visteon
Copyright © ESI Group, 2012. All rights reserved.
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PAM-RTM 2013
Product presentation
17
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composites Molding
Process Schematic
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SOFTEN PLIES PLACE IN TOOLS FORM EJECT PREFORM
TRIM PREFORM LOAD PREFORM INJECT RESIN CURE PART
DEMOLD PART FINAL PART
PA
M-F
OR
M 2
G
PA
M-R
TM
S
YS
PLY
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composite Molding simulation
To do what and how?
To define and optimize:
LCM strategy (RTM, CRTM, VARI…)
Location of injection gates, vents and vacuum ports
Size, type and location of flow media
Temperature cycle
Through the prediction of:
Filling and Curing time
Dry spots
Flow front velocity
Pressure in the mold
Taking into account
Fiber angle variation (permeability variation) of the preform
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B-Pillar injection
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composite Molding simulation
PAM-RTM flow model
Resin flow in a porous medium using
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Resin
inlet Resin
outlet
Section A
L
p
K
A
Q q
= = .
m3/s m2 Pa
m2 m/s Pas m
DARCY’S LAW
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composites Molding
Process variants with PAM-RTM
RTM: Resin Transfer Molding
Material data for simulation
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RTM HEATED RTM
OR
RTM HEATED RTM (added data)
Reinforcement Permeability tensor (K1,K2,K3) Constant OR f(shear angle)
Density Constant
Specific heat Constant OR f(temperature)
Thermal conductivity tensor (K1, K2, K3) Constant OR f(temperature)
Effective conductivity tensor (K1, K2, K3) Constant OR f(temperature) OR f(temperature, degree of cure)
Resin Density Constant
Viscosity constant OR f(time) OR f(material age)
Viscosity f(temperature) OR f(temperature, degree of cure) OR User defined
Specific heat Constant OR f(temperature) OR f(temperature, degree of cure)
Heat conductivity Constant OR f(temperature) OR f(temperature, degree of cure)
Enthalpy constant
Curing Kinetics 5 models including Kamal-Sourour OR User Defined
Floor panel TECABS project
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composites Molding
Process variants with PAM-RTM
VARI: Vacuum Assisted Resin Infusion
Material data for simulation (added data)
VARI (added data)
Reinforcement Permeability tensor (K1,K2,K3) f(fiber content)
Compressibility curve Pressure of compaction=f(fibre content)
VACUUM INFUSION
Wind blade infusion
Flexible membrane
Copyright © ESI Group, 2012. All rights reserved.
Liquid Composites Molding
Process variants with PAM-RTM
CRTM: Compression Resin Transfer Molding
Material data for simulation
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INJECT RESIN PARTIAL MOLD CLOSURE COMPRESSION STROKE
CRTM
Reinforcement Permeability tensor (K1,K2,K3) f(fiber content)
Automotive hood – A-CRTM
Courtesy: CCHP of Ecole Polytechnique of Montréal
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Post-Processing examples
Filling time
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30 meters wind spar cap infusion
Curing time
Fan blade of an aircraft engine RTM
Fuselage panel infusion
Filling degree
Courtesy: Airbus
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Post-Processing examples
Dry spots
Final part
Courtesy: Cranfield University
injection
injection
vent
racers injection Injection simulation / filling result
Dry spot prediction with PAM-RTM
Initial state Intermediate state Final state
Modified injection strategy
To avoid dry spots
vent
vent
injection
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PAM-RTM simulation
Additional functionalities
Porosity prediction and reduction:
Principle: Critical impregnation velocity:
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critfront vv
max
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PAM-RTM simulation
Additional functionalities
Porosity prediction and reduction:
PAM-RTM input data:
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0%
2%
4%
6%
8%
10%
12%
14%
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018 0.02
Flow velocity (m/sec)
Vo
ids
co
nte
nt
20 psi
30 psi
45 psi
2,5 ml/s
1.26+100.55*(V)
Chomarat - Roviply
12.824-1573.7*(V)
Macro-void
Micro-void
Optimum velocity
Based on experiment
Ca= viscosity*velocity/surface tension/contact angle
Experimental data PAM-RTM input curve
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Additional functionalities
Porosity prediction and reduction:
PAM-RTM output: injection flow rate curve
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(a) Constant injection pressure
(b) Constant injection flow rate
(c) Optimized injection flow rate
(a) Constant injection pressure
(b) Constant injection flow rate
(c) Optimized injection flow rate
0
1
2
3
4
5
6
7
0 50 100 150
injection time [sec]
inje
cti
on
flo
w r
ate
1e-7
[m
3/s
]
1E-04
1E-03
1E-02
Cap
illa
ry n
um
ber
at
flo
w f
ron
t
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Additional functionalities
Trigger manager that allows conditional opening of the
gates
DMP solving capability that highly decrease the
computation time when increasing the number of
processors
Gravity effect on resin flow
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0
2
4
6
8
0 10 20
Scale factor = f(# of processors)
CASE1700,000 elements
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Additional functionalities
One shot simulation (few seconds) for estimation
of last points to be filled and filling time
Automatic estimate of injection point location
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192
second
es 93
seconde
s
62
seconde
s
192 secondes
93 secondes
62 secondes
Copyright © ESI Group, 2012. All rights reserved.
What’s new in 2013?
Consolidation of DMP solver:
Permeability as a function of shear angle
Trigger manager
Reporting improvements
Results sampling on sensors
Specific heat and effective thermal
conductivity - f(T, alpha)
Material database
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Copyright © ESI Group, 2012. All rights reserved.
Liquid Composites Molding
PAM-RTM permeability database
Based on Nottingham University data available on ESI
customer portail: MyESI
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Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Workflow example (1/4)
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Ply lay-up
Fibers orientation
Material definition
Import
PAM-RTM
Solid mesh creation
and zones definition
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PAM-RTM simulation
Workflow example (2/4)
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Inlet definition
Flow media definition
PAM-RTM
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PAM-RTM simulation
Workflow example (3/4)
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PAM-RTM
Filling prediction
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM simulation
Workflow example (4/4)
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PAM-RTM
Zoom-in on flow media
influence on resin flow front
Copyright © ESI Group, 2012. All rights reserved.
PAM-RTM
Some References
Aston Martin
BOMBARDIER
BMW
CCAT
Dassault-Aviation
DOW
EADS
GE R&D
GE India Technology Center
Hexcel
M-Torres
ONERA
PPE
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Snecma and Snecma Propulsion
Solide (Safran Group)
TECSIS, IPT, FURG, Unifei
Volkswagen, VZLU
Ecole des Mines, Ecole
Polytechnique de Montréal,
Ecole Polytechnique de Nantes,
KU Leuven, Politecnico di
Milano, Shanghai Jiaotong
University, TU Clausthal, TU
Delft, TU Munchen, University of
Cranfield, University of
Nottingham, Wichita State
University…
http://www.esi-group.com/products/composites-plastics/pam-rtm/success-stories
Copyright © ESI Group, 2012. All rights reserved.