SUPR
Process Modelling for Manufacturing High Quality Lightweight Composites
Dnr:

NAISS 2023/5-526

Type:

NAISS Medium Compute

Principal Investigator:

Malin Åkermo

Affiliation:

Kungliga Tekniska högskolan

Start Date:

2024-01-01

End Date:

2024-07-01

Primary Classification:

20502: Composite Science and Engineering

Allocation

Abstract

Fiber reinforced composite materials are today an important material system for both the aerospace and automotive industry. This stems from their high specific strength and stiffness properties, enabling significant savings in the weight of the final product. Reducing weight is a critical challenge today for both the aerospace and automotive industry. This reduced weight translates to, lower energy consumption and thus emissions from aircraft and vehicles. However, manufacturing complex structures in a time and cost-efficient manner is still a challenge. Defects during the manufacturing process can knockdown the structural properties of the final part manufactured by up-to 40% [1]. Predicting these defects during the design phase can lead to huge savings in cost and enable manufacturing high quality defect-free composites parts. Our research group, here at KTH, has been working on this since 2012, and have been able to develop deep insights/knowledge in this field. Simulations are a key part of this process, see for instance [2]. The complexity of these simulation models are beyond the scope of standard workstations and require the use of supercomputers. Doctoral students, from the group have already been familiar with and put to use small allocations at DARDELL (NAISS 2023/22-1085). However, present projects require much larger allocations. The allocation from this round will primarily be put to use for two projects. The first project; SMARTER, aims at demonstrating how the use of state-of-the-art digital solutions can facilitate the manufacturing of robust, conforming and sustainable next generation lightweight aero-engine products while reducing the overall development cost and time-to-market. The project will make extensive use of process and structural numerical simulations early in the design process (Simulation-Driven Design) to optimize the design of a composite component. This will minimize physical prototype building, non-conforming products, material consumption and waste. The second project aims to develop and refine material models to capture the compaction/consolidation behavior of multi-stacked prepreg during the manufacturing process. Consolidation during the manufacturing process has been shown to be another major source of defects [3]. The focus would be on developing and refining User Defined Material Models (UMAT) with commercially available FE-Codes Reference: [1] L. D. Bloom, J. Wang, and K. D. Potter, ‘Damage progression and defect sensitivity: An experimental study of representative wrinkles in tension’, Compos. Part B Eng., vol. 45, no. 1, pp. 449–458, Feb. 2013, doi: 10.1016/j.compositesb.2012.05.021. [2] J. Sjölander, P. Hallander, and M. Åkermo, ‘Forming induced wrinkling of composite laminates: A numerical study on wrinkling mechanisms’, Compos. Part Appl. Sci. Manuf., vol. 81, pp. 41–51, Feb. 2016, doi: 10.1016/j.compositesa.2015.10.012. [3] J. P.-H. Belnoue, O. J. Nixon-Pearson, A. J. Thompson, D. S. Ivanov, K. D. Potter, and S. R. Hallett, ‘Consolidation-Driven Defect Generation in Thick Composite Parts’, J. Manuf. Sci. Eng., vol. 140, no. 7, p. 071006, Jul. 2018, doi: 10.1115/1.4039555.