rtm and vartm design, optimization, and control …automated design • selection of initial gate...

UD-CCM l 2 July 20031

RTM AND VARTM DESIGN, OPTIMIZATION, AND CONTROL WITH SLIC

Kuang-Ting HsiaoUD-CCM

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1. REPORT DATE 26 AUG 2004

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4. TITLE AND SUBTITLE RTM And VARTM Design, Optimization, And Control With SLIC

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6. AUTHOR(S) 5d. PROJECT NUMBER

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7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) University of Delaware Center for Composite Materials Newark, DE 19716

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13. SUPPLEMENTARY NOTES See also ADM001700, Advanced Materials Intelligent Processing Center: Phase IV., The original documentcontains color images.

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Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

2 July 2003© 2003 University of Delaware All rights reservedHsiao ONR Workshop - 2

The Resin Transfer Molding (RTM) Process

Preform lay-up

Mold closure

Resin injection

Cure and

Mold openingFabric cutting

Heat Flux


The Vacuum Assisted Resin Transfer Molding (VARTM) Process

Fiber preform

MoldCured part

Resin injectionResin impregnates

fibers and cures

Resin injection Fiber preformunder vacuum

Vacuum pump

Vacuum Bag


Governing Equations for RTM Flow Simulations

injPP =

∂∂

+∂∂

−=tP

KnP

KA

Q ntnnµinj

ventPP =

01

=

∂∂

+∂∂

−=tP

KnP

Ku ntnnn µ

or

j

iji x

PKu

∂∂

−=µ

Volume averaged velocity-pressure relationship for flow in porous media:

Darcy’s Law

Continuity equation for the Resin

0=∂∂

i

i

xu

0=

∂∂

∂∂

j

ij

i xPK

x µ


Simulation-based Liquid Injection Control: Philosophy

SLICSLIC

Artificial IntelligenceOptimized Design

For RTM/VARTM

Sensors & Recognition Algorithms

Process Monitoring

Control Algorithms

Feedback Control

Mesh

Preform PermeabilityFiber Volume Fraction

Resin ViscosityX

Y

Z


Features of SLIC

Layout of Flow Runners and Flow Distribution Media

Gates/Vents DesignMold Filling Monitoring and Characterization of Fiber Volume Fraction and Permeability

Online Mold Filling Control


Mesh Resin Viscosity

$$$$$$Cost Function& Constraints

SLICSLIC


Case 1: Optimize Gate and Vent LocationsInput

Length=1.50mWidth=1.00mHeight=0.20m-------------------------------------------------------Thickness = 0.01mKxx = Kyy = 1E-10 m^2Vf=0.5-------------------------------------------------------Resin Viscosity = 0.12 Pa-sec = 120 cps-------------------------------------------------------Injection Pressure = 3.03E+5 PaVent Pressure = 1.01E+5 Pa

Injection Gate

Vent

Optimized Mold Filling

SLICSLIC


Gate/Vent Candidates

Flow of Optimizing Gate(s)/Vent(s) with SLIC (Case 1)

Constraints and Cost Function f=f(Equip.Cost, Filling Time, Dry Spot)

Use Corresponding Macro(Either SLIC Default or

User Defined)

Select Desired Feature

Mesh (part.dmp)

SLICSLIC

Injection Gate

Vent


Case 2: A VARTM/Co-Cure Case Study

How to optimize the distribution network design?

VentGateFlow Channel

Distribution Layer

Preform

Pre-manufactured Ribs


Experimental Setup (for Case 2)


Trial and Error – 1 (for Case 2)

Fill Time ~ 19 min


Trial and Error – 2 (for Case 2)

Fill Time ~ 12 min


Trial and Error 4 - Expert Guess (for Case 2)

Fill Time ~ 11 min


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.


Case 2: A VARTM/Co-Cure Case Study

Pre-manufactured Rib Structure


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

Times for bottom surfaceExperiment

Match

SLIC

12 Experiments were conducted, the permeability ratio was obtained as 20-40.


Flow Distribution Network Design by SLIC

Fill Time ~ 13 min


Intuitive (Trial-and-Error) Design vs. SLIC’s Design

Final (fourth) intuitive design SLIC’s design


Case 3: A VARTM Case Study

D3: h = 5×h0

D2: h = 5×h0

L3: A =3× A0

L2: A =2× A0

Design 1Design 1

L1: A = A0

GateVent

D3: h = 4×h0 D2: h = 4×h0

L1: A = A0L2: A = 2×A0

Design 2Design 2L1=L2: A = A0

D1=D2=D3: h = 4×h0

Design 3Design 3

D: Distribution Media h0: Thickness of 1-ply distribution media L: Flow Runner A0: Cross-section Area of reference Flow Runner


Case 4: Steps on a Boat Deck (VARTM with Flow Runners)

Design 2Design 1 Design 3

Gate Vent Flow Runner


Permeability Variations

•Injection Pressure/Port

•Vent Pressure/Port

•Resin Viscosity

•Fiber Volume Fraction

•Permeability of the the Preform

LIMS

Characterization Challenges !Mold wall

Preform(fiber tows)

gap

Deformed fabricDraping overa tool surface

K and Vf change

??


Case 4: Using SLIC to Characterize the Racetracking

0

10

20

30

40

50

60

A B C D

E (La

ser) A B C D

E (La

ser) A B C D

E (La

ser)

Ave

rag

e ra

cetr

acki

ng

str

eng

th

Edge R1 Edge R2 Edge R3 Edge R4 Edge R5

The Standard deviation in racetracking strength by each operator can be as high as 80%.

R1

R2

R 3

R 4

R 5

Line injection

S1S2

S3

S4

S5

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.

A B C D

E (La

ser) A B C D

E (La

ser)


Streamlined Flow Monitoring & Control - From Design To Automation


Mesh Resin Viscosity

$$$$$$Cost Function& Constraints

Automated Mold Filling Monitoring & Control

Desired Performance & Process Constraints

Flow Detection/Monitoring Database

Flow Control Database

Equipment Installation Instructions

SLICSLIC


Developing Flow Sensing/Control System with SLIC

Hardware InstallationCode (HIC)

Vent

Pump

CAC 4

CAC 3

CAC 2

CAC 1

Control Action Code(CAC) for Each Disturbance Mode Controlled Results

Pum

p1 x 7 x

6 x

Number of Pumps, Lines,and Sensors to be used Potential Locations for

Gates/Vents/SensorsMesh and RacetrackingInformation

SLIC


Flow of Automation

SLIC

Computer

Simulation-based Liquid Injection Control (Intelligent Design Software)

Process Design•Hardware Installation Code•Dimensionless Time Vectors•Control Action Codes

Hardware

Setup

Instruction Operator (or Robot)

Vent

Installation(Hardware Setup)

Pum

p

LabView


Case 5: Online Flow Sensing/Control with SLIC

Injection gate with flow runner

Vent

…32 Disturbance Modes

Dry Spot Dry Spot

Dry Spot


Experiment Preparation (for Case 5)

Tekscan is laid on the bottom plate

Tekscan sensor

Fabrics and insert are placed on the top of Tekscan

FabricsInsert Sensor location

VENT

AG_1

AG_2IIL_1

IIL_2

AG: Auxiliary gate IIL: Initial injection line

Plexiglas Mold


Case 6: Online Flow Monitoring & Control with SLIC

Control action trigger sensor (CS)

Initial injection gate (IG) with flow runner

Auxiliary gate (AG)

Fixed vent

Disturbance detection sensor (DS)

Experimental resin arrival times

t0, t1, t2, t3, t4 are all collected

Disturbance Mode 29 is selected from the Database

Implement the customized control action for Mode 29

TekscanTM Sensor Area(Pressure Grid Film)

Control action Mode 29 is taking place. • CS1 >>> Close IG2• CS2 >>> Open AG1• CS3 >>> Close IG1• Vent Sensor >>> Close All Gates.

AG1

AG2

CS2IG1 IG2

CS1

CS3

Successful injection


Summary

SSLLIICCAUTOMATED DESIGNAUTOMATED 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 SLICAdvantages of developing RTM/VARTM with SLIC

•• Rapid design for RTM/VARTM.Rapid design for RTM/VARTM.

•• Less cost for process development.Less cost for process development.

•• Reliable and comprehensive mold filling solution.Reliable and comprehensive mold filling solution.

•• Advanced flow monitoring/control technology Advanced flow monitoring/control technology provides the opportunity to elevate the part provides the opportunity to elevate the part quality and reduce the cycle time.quality and reduce the cycle time.

PREFORM

RACETRACKING(DISTRUBANCE)

RESIN

00.20.40.60.8

1

0 0.02 0.04 0.06

µ

α (Τ)


Acknowledgements

Ø Professor Suresh G. AdvaniØ Ms. Delphine CoatlevenØ Mr. Mathieu DevillardØ Ms. Susanna LaurenziØ Mr. Dhiren ModiØ Mr. Yeshwanth Rao .K. NaveenØ Dr. Pavel Simacek

Ø Office of Naval Research (ONR)

rtm and vartm design, optimization, and control …automated design • selection of initial gate...

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