Composite Group Manufacturing Montana State University Pancasatya “Tiok” Agastra 27 November 2012.

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Presentation transcript:

Composite Group Manufacturing Montana State University Pancasatya “Tiok” Agastra 27 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 Navier-Stokes Equation with Darcy’s Law Conduction and Convection Enthalpy rate of release Autocatalytic Rate Law Integral Form of the Rate Law FLUID FLOW HEAT TRANSFER REACTION KINETICS

Manufacturing Methods RTMVacuum Bag

Manufacturing Parameter Quantification & Resin Characterization FlowrateTemperature 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 FLOWAXIAL FLOW Knytex D155 Cross Sectional Area

Heat Transfer Modeling RTMVacuum Bag

Fabric Compaction

COMSOL Coupled-Field Thermal-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