Composite Group Manufacturing Montana State University Pancasatya “Tiok” Agastra 27 November...

Composite Group ManufacturingMontana State University

Pancasatya “Tiok” Agastra27 November 2012

Impetus• Superior mechanical performance of large

composite structures through energy efficient manufacturing– Substructural details: ply drops, sandwich

construction, ply joints

• Low cost manufacturing and increased turnover rate

• Understanding of resin reaction kinetics

Approach• Quantification of manufacturing parameters

– Industry-accepted composite manufacturing method: Resin Transfer Mold (RTM), Vacuum Bag

• Manufacturing modeling using FEA– Fluid flow, including free surface analysis– Heat transfer with autocatalytic reaction kinetics– FEA packages: ANSYS FLOTRAN, ANSYS CFX,

COMSOL

Governing Equations for Manufacturing Modeling

uk

uuuu ηgρpρηtuρ T

Navier-Stokes Equation with Darcy’s Law

QTCρTtTCρ PP uk

Conduction and Convection

nm21 α1αkk

dtdα

α

0nm

21

t

0 α1αkkdαdt

αΔHHΔ Enthalpy rate of release

Autocatalytic Rate Law

Integral Form of the Rate Law

FLUIDFLOW

HEATTRANSFER

REACTIONKINETICS

Manufacturing MethodsRTM Vacuum Bag

Manufacturing Parameter Quantification & Resin Characterization

Flowrate Temperature

Differential Scanning Calorimetry

Manufacturing Milestone

Blade Root Manufacturing

“Brick” Laminate

Microflow-Scale Modeling• Resin flow in wind turbine blade materials is a complicated local and

global phenomenon (channel flow plus D’Arcy flow in strands)

Baseline Fiber Strand Permeability 6.16E-14 m²

Higher Fiber Strand Permeability 6.16E-12 m²

TRANSVERSE FLOW AXIAL FLOW

Knytex D155 Cross Sectional Area

Heat Transfer Modeling

RTM Vacuum Bag

Fabric Compaction

COMSOL Coupled-FieldThermal-Fluid-Convection

RTM with incoming resin

Large Scale Application

Future Work• Flow properties

– Viscosity and degree of cure correlation– Permeability and compaction

• Chemical and thermal properties– Thermal conductivity– Enthalpy release rates and heating rate