RTM AND VARTM DESIGN, OPTIMIZATION, AND CONTROL WITH SLIC. Kuang-Ting Hsiao UD-CCM

Transcription

1 RTM AND VARTM DESIGN, OPTIMIZATION, AND CONTROL WITH SLIC Kuang-Ting Hsiao UD-CCM UD-CCM 1

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3 The Resin Transfer Molding (RTM) Process Fabric cutting Heat Flux Cure and Mold opening Preform lay-up Resin injection Mold closure Hsiao ONR Workshop - 2

4 The Vacuum Assisted Resin Transfer Molding (VARTM) Process Fiber preform Mold Cured part Resin injection Vacuum Bag Fiber preform under vacuum Resin injection Resin impregnates fibers and cures Vacuum pump Hsiao ONR Workshop - 3

5 Governing Equations for RTM Flow Simulations Darcy s Law Volume averaged velocity-pressure relationship for flow in porous media: K ij P ui = µ x j K x i µ ij P x j = 0 Continuity equation for the Resin u x i i = 0 P = P vent P = P inj Q inj = A µ K nn P n + K nt or P t u n = 1 µ K nn P n + K nt P t = 0 Hsiao ONR Workshop - 4

6 X Simulation-based Liquid Injection Control: Philosophy Mesh Resin Viscosity Y Z SLIC Preform Permeability Fiber Volume Fraction Process Monitoring Feedback Control Artificial Intelligence Sensors & Recognition Algorithms Control Algorithms Optimized Design For RTM/VARTM Hsiao ONR Workshop - 5

7 Features of SLIC Mesh Resin Viscosity Gates/Vents Design Preform Permeability Fiber Volume Fraction SLIC Mold Filling Monitoring and Characterization of Fiber Volume Fraction and Permeability Layout of Flow Runners and Flow Distribution Media Hsiao ONR Workshop - 6 $$$ Cost Function & Constraints Online Mold Filling Control

8 Case 1: Optimize Gate and Vent Locations Input Optimized Mold Filling Vent Length=1.50m Width=1.00m Height=0.20m Thickness = 0.01m Kxx = Kyy = 1E-10 m^2 Vf= Resin Viscosity = 0.12 Pa-sec = 120 cps Injection Pressure = 3.03E+5 Pa Vent Pressure = 1.01E+5 Pa SLIC Injection Gate Hsiao ONR Workshop - 7

9 Flow of Optimizing Gate(s)/Vent(s) with SLIC (Case 1) Mesh (part.dmp) Gate/Vent Candidates Constraints and Cost Function f=f(equip.cost, Filling Time, Dry Spot) SLIC Vent Select Desired Feature Hsiao ONR Workshop - 8 Use Corresponding Macro (Either SLIC Default or User Defined) Injection Gate

10 Case 2: A VARTM/Co-Cure Case Study Flow Channel Distribution Layer Vent Pre-manufactured Ribs Gate Preform How to optimize the distribution network design? Hsiao ONR Workshop - 9

11 Experimental Setup (for Case 2) Hsiao ONR Workshop - 10

12 Trial and Error 1 (for Case 2) Hsiao ONR Workshop - 11 Fill Time ~ 19 min

13 Trial and Error 2 (for Case 2) Hsiao ONR Workshop - 12 Fill Time ~ 12 min

14 Trial and Error 4 - Expert Guess (for Case 2) Hsiao ONR Workshop - 13 Fill Time ~ 11 min

15 Procedure Optimizing Distribution Layers and Runner Channels with SLIC 1. Create Finite Element Mesh (Geometry) of the composite part. 2. Collect Permeability/Fiber Volume Fraction of the Preform. 3. Characterize the Permeability of the Distribution Media by using SLIC. 4. Calculate the Effective Permeability of the Flow Runner Channels. 5. Use SLIC to optimize the placement of Distribution Media and Flow Runner Channels. Run an experiment to verify the design. Hsiao ONR Workshop - 14

16 Case 2: A VARTM/Co-Cure Case Study Pre-manufactured Rib Structure Hsiao ONR Workshop - 15

17 Distribution Layer Permeability Measurement with SLIC Permeability ratio of the distribution layer and the preform is assumed as 5, 10, 15,,150. Times for top surface SLIC Experiment Times for bottom surface Match 12 Experiments were conducted, the permeability ratio was obtained as Hsiao ONR Workshop - 16

18 Flow Distribution Network Design by SLIC Hsiao ONR Workshop - 17 Fill Time ~ 13 min

19 Intuitive (Trial-and-Error) Design vs. SLIC s Design Final (fourth) intuitive design SLIC s design Hsiao ONR Workshop - 18

20 Case 3: A VARTM Case Study Gate Vent D3: h = 5 h 0 D: Distribution Media h 0 : Thickness of 1-ply distribution media L: Flow Runner A 0 : Cross-section Area of reference Flow Runner Design 1 Design 2 D3: h = 4 h 0 D2: h = 4 h 0 Design 3 L1=L2: A = A 0 L3: A =3 A 0 D2: h = 5 h 0 L1: A = A 0 L2: A =2 A 0 L2: A = 2 A 0 L1: A = A 0 D1=D2=D3: h = 4 h 0 Hsiao ONR Workshop - 19

21 Case 4: Steps on a Boat Deck (VARTM with Flow Runners) Design 1 Design 2 Design 3 Gate Vent Flow Runner Hsiao ONR Workshop - 20

22 Permeability Variations?? Injection Pressure/Port Vent Pressure/Port Resin Viscosity Fiber Volume Fraction Permeability of the the Preform Characterization Challenges! Mold wall gap LIMS Deformed fabric Draping over a tool surface Hsiao ONR Workshop - 21 Preform (fiber tows) K and V f change

23 Case 4: Using SLIC to Characterize the Racetracking R 5 S5 S3 R 4 R 3 R2 S2 S1 Line injection Five different operators A, B, C, D and E run 10 experiments each. A, B, C and D cut the fabrics by hands, E used a laser cutter. S4 R1 Average racetracking strength Hsiao ONR Workshop - 22 Edge R1 Edge R2 Edge R3 Edge R4 Edge R5 A B C D E (Laser) A B C D E (Laser) A B C D E (Laser) The Standard deviation in racetracking strength by each operator can be as high as 80%. A B C D E (Laser) A B C D E (Laser)

24 Streamlined Flow Monitoring & Control - From Design To Automation $$$ Cost Function & Constraints SLIC Equipment Installation Instructions Flow Detection/Monitoring Database Mesh Resin Viscosity Flow Control Database Preform Permeability Fiber Volume Fraction Desired Performance & Process Constraints Hsiao ONR Workshop - 23 Automated Mold Filling Monitoring & Control

25 Developing Flow Sensing/Control System with SLIC 1 x 7 x Pump 6 x Number of Pumps, Lines, and Sensors to be used Potential Locations for Gates/Vents/Sensors Mesh and Racetracking Information SLIC Pump Vent Hardware Installation Code (HIC) CAC 1 CAC 2 CAC 3 CAC 4 Control Action Code (CAC) for Each Disturbance Mode Controlled Results Hsiao ONR Workshop - 24

26 Flow of Automation Simulation-based Liquid Injection Control (Intelligent Design Software) SLIC Process Design Hardware Installation Code Dimensionless Time Vectors Control Action Codes Computer Hardware Setup Instruction Operator (or Robot) Installation (Hardware Setup) LabView Pump Hsiao ONR Workshop - 25 Vent

27 Case 5: Online Flow Sensing/Control with SLIC Injection gate with flow runner Vent Dry Spot 32 Disturbance Modes Hsiao ONR Workshop - 26 Dry Spot Dry Spot

28 Experiment Preparation (for Case 5) Insert Tekscan Sensor sensor location Fabrics AG_1 IIL_1 AG_2 IIL_2 Plexiglas Tekscan Mold VENT Fabrics and is insert laid on are the placed bottom on plate the top AG: Auxiliary gateof IIL: Tekscan Initial injection line Hsiao ONR Workshop - 27

29 Case 6: Online Flow Monitoring & Control with SLIC Tekscan TM Sensor Area (Pressure Grid Film) Initial injection gate (IG) with flow runner Fixed vent Auxiliary gate (AG) Disturbance detection sensor (DS) Control action trigger sensor (CS) Hsiao ONR Workshop - 28 IG1 Experimental resin arrival times t 0, t 1, t 2, t 3, t 4 are all collected AG1 CS2 CS1 AG2 CS3 IG2 Disturbance Mode 29 is selected from the Database Implement the customized control action for Mode 29 Control action Mode 29 is taking place. CS1 >>> Close IG2 CS2 >>> Open AG1 CS3 >>> Close IG1 Vent Sensor >>> Close All Gates. Successful injection

30 Summary PREFORM RACETRACKING (DISTRUBANCE) RESIN m a (T) SLIC AUTOMATED DESIGN Selection of Initial Gate and Vent Locations Optimization of the Flow Distribution Network Online Flow Sensing/Permeability Characterization System Design Creation of Online Flow Control Solution Advantages of developing RTM/VARTM with SLIC Rapid design for RTM/VARTM. Less cost for process development. Reliable and comprehensive mold filling solution. Advanced flow monitoring/control technology provides the opportunity to elevate the part quality and reduce the cycle time. Hsiao ONR Workshop - 29

31 Acknowledgements Professor Suresh G. Advani Ms. Delphine Coatleven Mr. Mathieu Devillard Ms. Susanna Laurenzi Mr. Dhiren Modi Mr. Yeshwanth Rao.K. Naveen Dr. Pavel Simacek Office of Naval Research (ONR) Hsiao ONR Workshop - 30