Simulation of Composite Manufacturing Processes

Simulation of Composite Manufacturing Processes
Introduction
Yann Duplessis Kergomard / Santiago Montagud Perez de Lis – ESI Group,

CoE Composite Manufacturing – ydk@esi-group.com / smo@esi-group.com
Octobre 2020
www.esi-group.com 1
Copyright © ESI
Copyright
Group, ©
2015.
ESI Group,
All rights
2015.
reserved.
All rights reserved.
ESI short presentation
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Copyright © ESI Group, 2015. All rights reserved.
The Story of ESI
Image courtesy of Volkswagen AG Image courtesy of AP&T
1973 1985 1999 2000
THE STORY FIRST CRASH TEST VIRTUAL NYSE EURONEXT

BEGINS ON FULL CAR MANUFACTURING ESI enters the NYSE
ESI founded; expert First Volkswagen Polo Added to the ESI portfolio: Euronext Paris
in physics of materials • Casting stock market
• Sheet Metal Forming
• Welding
ISO 9001-2000 CERTIFICATION
www.esi-group.com 3
The Story of ESI
2001 2011 2012 2016
EXPANSION INTO ENTRY INTO VIRTUAL EMBRACING OPEN MAKE IT SMART

MULTI-DOMAIN REALITYv SOURCE
SIMULATION ESI acquires IC.IDO ESI acquires OpenCFD, the ESI makes prototypes smart by
• NVH makers of OpenFOAM integrating acquisitions in Systems
• Durability Engineering, Cloud Computing,
• Vibro-Acoustics Data Analytics and Machine
• Comfort Learning
Image courtesy of Mitsubishi Hitachi Power Systems Europe
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ESI Around The World
More than 40 countries 34 subsidiaries 1100 people
MILPITAS, CA DETROIT, MI SÃO PAULO PARIS FRANKFURT EKATERINBURG BANGALORE BEIJING TOKYO
USA USA BRAZIL FRANCE GERMANY RUSSIA INDIA CHINA JAPAN
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( YDK note: here slides from for industrial trade
presentation)
Virtual Prototyping to Drive Innovation
Image courtesy of Vesta Engheneria Image courtesy of Audi AG
www.esi-group.com 6
Copyright © ESI
Copyright
Group, ©
2015.
ESI Group,
All rights
2015.
reserved.
All rights reserved.
( YDK note: here slides from for industrial trade
A Complete & Integrated Offer presentation)
Virtual Manufacturing End-to-End Solutions
Casting Composites Sheet Metal Forming Welding & Assembly Virtual Performance Virtual Seat Solution
Solution
Virtual Performance
Crash & Safety NVH & Dynamics Interior Acoustics Statics & Strength Vibro-Acoustics
Virtual Environment Virtual Integration Platform Virtual Reality Engineering services
CFD & Multiphysics Electromagnetics Multi-Domain Decision Support Collaborative Consulting Services
Simulation decision-making
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Images courtesy of Fonderia Casati, AP&T, Škoda Auto, Volkswagen AG, EADS Casa Espacio and Ford.

Composite Materials
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Arnaud Dereims (ESI Group) – Oct. 9th 2015 – ENSEIRB MATMECA
Composite Materials
What is it?
• Assembly of, at least, two

immiscible materials
• Exhibits new properties absent

from individual constituent
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Composite Materials
What is it?


from individual constituent Composite structures
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Composite Materials
What is it?


from individual constituent Composite structures
Well known composite materials
Composite part manufacturing processes
Composite Materials
Fibre Reinforced Polymer (FRP)
Fibres
+
Organic Matrix
Composite Materials
Fibres Fibre : ϕ ~ 0,01mm
+
Organic Matrix
Composite Materials
+ Yarn
Organic Matrix
Composite Materials
+ Yarn
Organic Matrix
Ply
Composite Materials
Fibres
+
Organic Matrix
Composite Manufacturing Processes
Overview of CFRP Manufacturing Processes
Liquid Composite Moulding

(LCM)
• 3 steps
‣ Preforming
‣ Impregnation
‣ Curing/Cooling
Liquid Composite Moulding Pre-Impregnated semi-product

(LCM) (Prepregs)
• 3 steps • 2 steps
‣ Preforming ‣ Thermoforming
‣ Impregnation ‣ Curing/Cooling
‣ Curing/Cooling

(LCM) (Prepregs)
Supplier
‣ Curing/Cooling

(LCM) (Prepregs)
Supplier
‣ Curing/Cooling
Composite manufacturing issues by industries
Industrial issues : Aeronautic industry
Simulation time divided by 5 thanks to simulation
Better quality parts with less scraps (better reproducibility)
• Medium to large parts

• Main constraints:
‣ Part design cannot be modified easily
• Processability of the designed part
• Process design cost
‣ Manufactured part quality (very few porosity,
no distortion…)
• New constraints:
‣ Manufacturing time and cost
G_MKT_RL_10_345, Courtesy of EADS Innovation Works,

Infusion simulation of a fuselage panel with PAM-RTM
G_MKT_R_L_13_255, Courtesy of VZLÚ
Industrial issues : Wind industry
160 m φ
Source : « Wind energy use in Germany –
Status 31.12.2006 » , DEWI Magazine Nr.
30, Feb 2007
• Large to very large parts

• Some region very thick (> 10 cm) Airbus
A380
Wing span
‣ Size of the parts: 80 m
• Processability of the designed part
• Process design cost
‣ Manufactured part quality for the critical
structural part (spar)
‣ Manufacturing and material cost
An 81.6 meter long offshore wind turbine rotor blade & Analysis of several injection strategies with PAM-RTM on the root of the rotor blade
G.MKT.R.L14.625
Industrial issues : Automotive industry
• Small to medium parts

‣ Material cost
‣ Manufacturing time window (<
2-3’) and cost
• Processability of the designed
part
Floor pan
• Process design cost injection
RTM application: Automotive floor panel
Simulation of composite manufacturing processes at
ESI
ESI PAM-COMPOSITES
Summary
Compensated
Mold
Geometry
Distortion analysis
PAM-DISTORTION
LCM – Curing analysis Temperature

PAM-RTM & Degree of Cure
history
Pre-forming analysis Shearing of

PAM-FORM fibers
What for ?
What for ?
Impregnation of dry preform with resin and curing
• HP-RTM
• Curing
• …
• RTM • Infusion • C-RTM
How to simulate and Why
Why simulate LCM process ?
To Determine and Optimize process parameters such as:

• Process parameters: • Material / Design
‣ locate injection gates and vents • Material behavior f(T, t)
‣ Flow rates or pressure • Ply book
‣ Vacuum • Design of new molds or improvement of existing molds
‣ Temperature cycle
Through prediction of:

• Air traps • Temperature evolution
• Micro porosity • Degree of cure evolution
• Injection time • Pressure in the mold
Physics involved
Physics involved: Modelling

• Four physical phenomena are modeled
‣ Flow of resin inside the preform
‣ Heat exchanges inside reinforcement and mould
‣ Chemical reaction of resin
‣ Reinforcement deformation in case of infusion
Physics involved: reinforcement modelling
Fibres
+
Organic Matrix
Physics involved: Preform modelling
tows fibers
Micro voids
Macro voids
Macroscopic Meso-scopic Microscopic
tow
Preform modelling
Physics involved: Preform modelling
Solid Mechanics Fluid Mechanics
Macro-scale
deformable preform made of undeformable filaments Porous medium approximation

𝐽 𝑥,
Ԧ 𝑡 + ∆𝑡 𝑣𝑓 𝑥,
Ԧ 𝑡 + ∆𝑡 = 𝐽 𝑥,
Ԧ 𝑡 𝑣𝑓 (𝑥,
Ԧ 𝑡)
Darcy law / permeability
Flow Modeling
Darcy’s Experiment
F i n d e l ’ I nt ro d u c t i o n
Copyright © ESI Group, 2014.
2015. All rights reserved.

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Yann Duplessis Kergomard / Santiago Montagud Perez de Lis – ESI Group,

Image courtesy of Volkswagen AG Image courtesy of AP&T

1973 1985 1999 2000

THE STORY FIRST CRASH TEST VIRTUAL NYSE EURONEXT

2001 2011 2012 2016

EXPANSION INTO ENTRY INTO VIRTUAL EMBRACING OPEN MAKE IT SMART

Image courtesy of Mitsubishi Hitachi Power Systems Europe

More than 40 countries 34 subsidiaries 1100 people

Virtual Prototyping to Drive Innovation

Image courtesy of Vesta Engheneria Image courtesy of Audi AG

Virtual Manufacturing End-to-End Solutions

Virtual Environment Virtual Integration Platform Virtual Reality Engineering services

Copyright © ESI Group, 2015. All rights reserved.

• Assembly of, at least, two

• Exhibits new properties absent

• Assembly of, at least, two

• Exhibits new properties absent

• Assembly of, at least, two

• Exhibits new properties absent

Well known composite materials

Fibres Fibre : ϕ ~ 0,01mm

Fibres Fibre : ϕ ~ 0,01mm

Fibres Fibre : ϕ ~ 0,01mm

Liquid Composite Moulding

Liquid Composite Moulding Pre-Impregnated semi-product

Liquid Composite Moulding Pre-Impregnated semi-product

Liquid Composite Moulding Pre-Impregnated semi-product

• Medium to large parts

G_MKT_RL_10_345, Courtesy of EADS Innovation Works,

G_MKT_R_L_13_255, Courtesy of VZLÚ

• Large to very large parts

• Small to medium parts

RTM application: Automotive floor panel

LCM – Curing analysis Temperature

Pre-forming analysis Shearing of

Impregnation of dry preform with resin and curing

• RTM • Infusion • C-RTM

To Determine and Optimize process parameters such as:

Through prediction of:

Physics involved: Modelling

‣ Flow of resin inside the preform

‣ Heat exchanges inside reinforcement and mould

‣ Chemical reaction of resin

‣ Reinforcement deformation in case of infusion

Macroscopic Meso-scopic Microscopic

Solid Mechanics Fluid Mechanics

deformable preform made of undeformable filaments Porous medium approximation

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