Milestones: Sensors, Control and Automation Group NSF/DOE/APC Workshop: The Future of Modeling in Composites Molding Processes June 9-10, 2004

Composites Processing Laboratory, University of Connecticut Milestones: Thermoplastic-matrix Composites Processing Three-to-Five year Milestones qCharacterize material variability (batch-to-batch, for example) and systematically understand its effects on the processing, the part quality, and properties. qIn-process and Post-process sensing: 3D imaging of parts online with the process to measure warpage and dimensional changes relative to the CAD drawing. Feedback post-process sensing to process modeling qIn-situ fiber orientation, fiber length, homogeneity sensing mHomogeneity across the part mSystematic flow visualization studies to understand dominant effects, to guide modeling qCrystallization and morphology evolution under molding conditions (shear rates and thermal conditions) and relationship to properties

Composites Processing Laboratory, University of Connecticut Milestones: Thermosetting-matrix Composites Processing Three-to-Five year Milestones qDetailed materials characterization and variability quantification (kinetics, rheology, permeability,…); batch-to-batch and spatial variability qStochastic modeling and analysis—at a system level—incorporating parameter variability. Longer term milestone: to address issues leading to the variability, so as to minimize the uncertainty. qReliable, low-cost sensor development: in-process sensing for permeability mapping, flow and cure monitoring. qActive control for nonisothermal liquid molding qEfficient computational strategies and establishment of a common paradigm of integration of component models

Composites Processing Laboratory, University of Connecticut Product/Process Design Example Integrated product and process design for short fiber reinforced polymer composites qStiffness and strength defined by fiber direction during manufacturing qIPPD enabling technologies mold filling fiber orientation material properties product performance polymer melt flow analysis static stress analysis modal analysis thermal stress analysis mold filling simulation fiber orientation prediction material property calculation mold cooling analysis warpage simulation numerical optimization design sensitivity analysis multidisciplinary design methodologies structural optimization UNCERTAINTY QUANTIFICATION Post-processing Inspection and Feedback to processing