High-Fidelity Digital Twin Autoclave Tool for Quality Informed Composite Fabrication

Jim Lua, Kalyan Shrestha, Anand Karuppiah, Jinhui Yan, Ian Guay, Nam D. Phan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The Autoclave processing is commonly used in manufacturing high-performance fibre-reinforced thermoset composite components in the aerospace industry. Variations in the cure cycle, sometimes even apparently minor deviations from the prescribed cure cycle, can harm the laminate properties. Given the costly and time-consuming autoclave manufacturing process, there is a strong need to cure the maximum number of parts in the shortest possible time without compromising quality. In order to achieve high-rate automated manufacturing with the optimized autoclave process, it is important to construct a digital twin modelling approach to mirror the physical composite curing process in the virtual domain based on the integration of high-fidelity multi-physics models. The resulting digital twin includes a thermal CFD model, a thermo-chemo-mechanical module, and an efficient and accurate block coupling between these two modules. The customized Abaqus driven by local and spatial variation of the turbulence-induced heat transfer coefficient (HTC) imposed through one-way coupling determines the thermo-mechanical response in composite parts. Using the developed digital twin tool (SMARTCLAVE), HTC's spatial and temporal variation can be generated digitally without invoking an expensive and time-consuming experimental approach. The predicted local boundary conditions are used in SMARTCLAVE to determine the cure kinetics, temperature distribution, and thermal-mechanical response that drives the residual stress and distortion of composite parts after curing. The accuracy of the digital twin for autoclaving is demonstrated first using a benchmark problem followed by the capability demonstration with a single-part L-beam assembly. The benefits of using the digital twin tool are illustrated via the optimal placement of multiple parts in an autoclave to balance the throughput and quality.

Original languageEnglish (US)
Title of host publicationVertical Flight Society 80th Annual Forum and Technology Display
PublisherVertical Flight Society
ISBN (Electronic)9781713897941
StatePublished - 2024
Event80th Annual Vertical Flight Society Forum and Technology Display, FORUM 2024 - Montreal, Canada
Duration: May 7 2024May 9 2024

Publication series

NameVertical Flight Society 80th Annual Forum and Technology Display

Conference

Conference80th Annual Vertical Flight Society Forum and Technology Display, FORUM 2024
Country/TerritoryCanada
CityMontreal
Period5/7/245/9/24

ASJC Scopus subject areas

  • Aerospace Engineering
  • Control and Systems Engineering

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