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Session: Poster pitches day 1
Session starts: Monday 26 June, 09:50
Presentation starts: 09:50

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Jim Lua (Global Engineering and Materials, Inc.)
Kalyan Shrestha (Global Engineering and Materials, Inc.)
Ze Zhao (University of Illinois)
Jinhui Yan (University of Illinois)
Nam Phan (NAVAIR)

Abstract:
Variations in the cure cycle, sometimes even apparently minor variations, can harm the laminate properties. Advances in autoclave technology, including modern control systems and new duct and heater configurations, lead to overall composite quality improvements. Given the costly and time-consuming process, there is a strong need to cure the maximum number of parts in the shortest possible time without compromising quality. This study is focused on the development of a versatile, user-friendly, and computationally efficient toolkit for virtual simulation of local environmental conditions in an autoclave with multiple parts to maximize the throughput with the correct cure profile of each part. A coupled immersogeometric thermal CFD and aerodynamics-aided heat transfer module with a consistent LES turbulence model (without ad hoc viscosity) is developed to capture the turbulence-induced local boundary conditions and the resulting thermal and pressurization response of multiple parts in an autoclave. A hybrid shell and solid element modeling approach in CFD and its associated immersogeometric modeling is implemented to greatly enhance the computational efficiency. The predicted time history of the surface temperature of the tool and the associated composite part were used in the user-defined Abaqus heat transfer (UMATHT) and stress analysis module (UMAT) to determine the distortion, thermal shrinkage-induced surface wrinkling, and residual stress. Due to the exothermic nature of the resin curing process, internal heat generation is included in the developed heat transfer analysis module that incorporates a resin cure kinetics model in UMATHT. The resulting SMARTCLAVE toolkit is validated first by using data collected at coupon and component levels. The use of the digital twin autoclave tool is demonstrated to achieve improved fabrication quality.