Spring-In – Simulation in Fiber-

Composite Manufacturing

T. Spröwitz, T. Wille, M. Kleineberg, J. Tessmer

ECCM 13
2.-5. June 2008, Stockholm, Sweden

Institute of Composite Structures and Adaptive Systems

Contents

Motivation
Material Parameter Identification
Analysis of curved Profile
Conclusions

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Motivation
High production rate (≥ 30AC / month)
Extreme competition on world market (low earnings / AC)
Part production costs and component assembly costs
Æ Minimize rejection rate (max. reproducibility)
Æ Minimize cycle times (optimal usage of technical equipment)
Æ Low-shim assembly
σΩ
Allowable
Stresses

Quelle: Seatle Times Quelle: AIRBUS

Manufacturing Fitting Position Test / In-Service Time

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 Motivation – General Approach d
a

tnominal = laminate thickness

tRT = laminate thickness after curing
tnominal d = thickness shrinkage
tRT a = laminate movement
Δθspring-in Δθ = spring-in

l outer: length outer fibre

(assumed to be constant)

Determination of shrinkage
linner: length inner fibre
(assumed to be constant)

parameters using FEM

(Nastran) and test results Fibre dominated
In Plane
Properties
Matrix dominated
Out of Plane Properties

Determination of Spring-In
Experimental on generic aircraft frame
determination of Spring- structure
in on L-profile under
different process cycles

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Step 1: Experimental Determination of Spring-In

Invar RTM 200

mould with 180

integrated
160

140
thermocouples 120

100

Reproducable 80

manufacturing
T V1, Normal
T V2, Tgel 180°
60
T V3, Tgel 130°

using heatable 40
T V7, Tgel 110°

press 20

0
0 100 200 300 400 500 600 700 800 900

Measurement of
spring-in angle Variation of process parameters
(variation of gel point)

Fiber: HTS
Matrix: RTM6
Laminate: [4*(±45)]s

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 Step 2: Material Parameter Identification
Iso-static
mounting

Layerwize modeling with solid

elements [HEX8]
3d
(3 elements per single ply)
2d
Fitting
position

Determination of modified CTE of a unidirectional single ply

1. αF =const, αM adjusted αM = αMT + αMC

2. Calculation of homogenized properties of unidirectional single ply using ESAComp3.4
3. Linear-static FEM simulation of L-profile with modified CTE of unidirectional single plies
4. Matching with experimentally determined Spring-In angles by variation of αMC
5. Validation analyses for different fiber-volume-fractions

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 Step 2: Material Parameter Identification
200

1. Variation of fiber-CTE 180

αF11 from literature survey 160

leads to negligible 140

changes of the Spring-In 120

angle 100

80
T V1, Normal
T V2, Tgel 180°
60
T V3, Tgel 130°
T V7, Tgel 110°
40

20

2. Matching with 0 100 200 300 400 500 600 700 800 900

experimental results for

minimal Spring-In Disp. at Disp. at
Disp. Δx β
αF11 αM x1 x2
[mm] [mm] [deg]
[mm] [mm]
-0.38·10-6 40.0·10-6 0.590 0.0473 0.5828 0.5355 0.495
3. Matrix CTE αMT through -0.38·10-6 50.0·10-6 0.704 0.0574 0.6957 0.6383 0.590
parameter variation -0.38·10-6 57.2·10-6 0.786 0.0646 0.7765 0.7719 0.658
(assumption: thermal part -0.38·10-6 62.0·10-6 0.841 0.0694 0.8310 0.7616 0.704
only) -0.38·10-6 69.0·10-6 0.921 0.0765 0.9100 0.8335 0.770
-0.38·10-6 80.0·10-6 1.047 0.0876 1.0340 0.9464 0.875

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Step 2: Material Parameter Identification

¾ Good correlation between experimental

results and analysis for the different
fiber-volume-fractions

¾ Analytical results lead to lower Spring-In

angles

⎡ (α − α R ) ⋅ ΔT ⎤
Δθ = θ ⋅ ⎢ T ⎥
⎣ 1 + α R ⋅ ΔT ⎦

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Step 2: Material Parameter Identification

Displacements in Stresses under iso-static Stresses in fitted position

iso-static mounting mounting

Max. Pressure: -68 N/mm² Max. Pressure: -158 N/mm²

Max. Tension: +68 N/mm² Max. Tension: +70 N/mm²

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Step 3: Profile Analysis

Profiles that
have been
investigated
Integral
Z-Profiles
2D / 3D
Hybrid UD
Models Integral Reinforced
Z-Profiles Inner and
Middle
Chord
Integral
LCF-Profiles

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 Step 3: Profile Analysis – Boundary Conditions

Iso-static mounting on free edge Mounted in fitting position

Æ Global Spring-In angle Æ Stress analysis

Æ Residual stress analysis

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Step 3: Profile Analysis – Simulation Results

Global Spring-In Effect:

Æ Global Radius Decreases
Integral
Z-Profiles

Global Spring-In Effect:

UD Æ Global Radius Increases
Integral
Z-Profiles

Global Spring-In Effect:

UD Æ Global Radius Decreases
Integral
LCF-Profiles UD

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Step 3: Z-Profile Analysis – Displacements and Stresses

Nominal frame radius rnom = 1975.0mm

Measured radius rmes = 1963.5mm
Process P1 P2 P3 P4
Global Radius 1964.5 1963.0 1967.1 1968.9

Æ Good agreement with measured global radius

Stresses:

Process P1 P2
Fiber Stresses Chords [Mpa] -63 – 33 -125 – 65
Fiber Stresses Frame [Mpa] -33 – 53 -65 – 102
Matrix Stresses [MPa] 30 – 34 58 – 70

Æ No significant changes of stresses in

fitting position

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Conclusions

Spring-In deformation is highly dependent on

gel-temperature and fibre-volume-fraction

Æ Reproducible process conditions required for cost effective, high

precision manufacturing

Simple L-shaped coupons can be used to investigate the Spring-In behaviour of

complex composite structures

Æ Realisation of Spring-In compensated manufacturing moulds possible

Lower gel-temperatures lead to reduced Spring-In angles but also increase

cycle times significantly

Æ Reduced Spring-In angles indicate a lower stress level in the laminate

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Thank you
for your
attention!
Contact: Tom Sproewitz
DLR German Aerospace Center
Institute of Composite Structures and Adaptive Systems
Lilienthalplatz 7
D-38108 BRAUNSCHWEIG
Email: tom.sproewitz@dlr.de
Phone: +49-531-295-2343

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