slic simulation-based liquid injection control

UNIVERSITY OF DELAWARE CENTER FOR COMPOSITE MATERIALS iNTKHNAnONALtr RECOCNiZED EXCELLENCE

SLIC SIMULATION-BASED LIQUID INJECTION CONTROL

Kuang-Ting Hsiao

UD-CCM

l

1 July 2003

Form Approved OMB No. 0704-0188

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26 AUG 2004

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4. TITLE AND SUBTITLE

5a. CONTRACT NUMBER

SLIC Simulation-Based Liquid Injection Control

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6. AUTHOR(S)

5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

University of Delaware Center for Composite Materials Newark, DE 19716 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

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Approved for public release, distribution unlimited 13. SUPPLEMENTARY NOTES

See also ADM001700, Advanced Materials Intelligent Processing Center: Phase IV., The original document contains color images. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: a. REPORT

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

Simulation-based Liquid Injection Control: Philosophy Mesh

Resin Viscosity

C~

X Y Z

SLIC Preform Permeability Fiber Volume Fraction

-t

Process Feedback Monitoring Control

Artificial Intelligence

Sensors & Recognition Algorithms

Optimized Design For RTM/VARTM

Control Algorithms Hsiao ONR Review - 2

© 2003 University of Delaware All rights reserved

1 Jul 2003

Features of SLIC Mesh

Resin Viscosity

i Gates/Vents Design

Preform Permeability Fiber Volume Fraction

Mold Filling Monitoring and Characterization of Fiber Volume Fraction and Permeability

SLIC

$$$ Layout of Flow Runners and Flow Distribution Media Hsiao ONR Review - 3

Cost Function & Constraints © 2003 University of Delaware All rights reserved

Online Mold Filling Control 1 Jul 2003

Case 1: Optimize Gate & Vent Locations Input

Cost Function

Optimized Mold Filling Vent

Length=1.50m Width=1.00m SLIC Height=0.20m ------------------------------------------------------Thickness = 0.01m Kxx = Kyy = 1E-10 m^2 Vf=0.5 ------------------------------------------------------Resin Viscosity = 0.12 Pa-sec = 120 cps ------------------------------------------------------Injection Pressure = 3.03E+5 Pa Vent Pressure = 1.01E+5 Pa Hsiao ONR Review - 4

© 2003 University of Delaware All rights reserved

Injection Gate

1 Jul 2003

Case 2: A VARTM/Co-Cure Case Study Pre-manufactured Rib Structure

Hsiao ONR Review - 5

© 2003 University of Delaware All rights reserved

1 Jul 2003

Distribution Layer Permeability Measurement with SLIC (Case 2) Permeability ratio of the distribution layer and the preform is assumed as 5, 10, 15,…,150. Times for top surface

SLIC Experiment

Times for bottom surface

Match 12 Experiments were conducted, the permeability ratio was obtained as 20-40. Hsiao ONR Review - 6

© 2003 University of Delaware All rights reserved

1 Jul 2003

Intuitive (Trial-And-Error) Design vs. SLIC’s Design (Case 2) Number of distribution media layer

! 0 Point vent

i

Infusion line

Number of distribution media layer

Point vent Infusion line

Simulations

Very small final dry spot

Simulations

Experimental results (mirrored images)

Experimental results (murored .mages)

Processing time

Final (fourth) intuitive design

Hsiao ONR Review - 7

Processing tune

SLIC’s design

© 2003 University of Delaware All rights reserved

1 Jul 2003

Case 3: A VARTM Case Study D: Distribution Media L: Flow Runner

Gate Vent

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

Design 1 D3: h = 5×h0

Design 2 D3: h = 4×h0

D2: h = 4×h0

Design 3 L1=L2: A = A0

L3: A =3× A0 D2: h = 5×h0

L1: A = A0

L2: A =2× A0

Hsiao ONR Review - 8

L1: A = A0 L2: A = 2×A0

© 2003 University of Delaware All rights reserved

D1=D2=D3: h = 4×h0

1 Jul 2003

Case 4: Steps on a Boat Deck (VARTM with Flow Runners) Design 1

Gate

Hsiao ONR Review - 9

Design 2

Vent

© 2003 University of Delaware All rights reserved

Design 3

Flow Runner

1 Jul 2003

Permeability Variation in Process •Injection Pressure/Port •Vent Pressure/Port

LIMS

•Resin Viscosity

? ?

•Fiber Volume Fraction •Permeability of the the Preform Characterization Challenges ! Mold wall

Deformed fabric Draping over a tool surface

gap

Air channel (gap) Hsiao ONR Review - 10

Preform (fiber tows)

K and Vf change

© 2003 University of Delaware All rights reserved

1 Jul 2003

Streamlined Flow Monitoring & Control - From Design To Automation $$$

Equipment Installation Instructions

Cost Function & Constraints

SLIC

Flow Detection/Monitoring Database Flow Control Database

Mesh

Resin Viscosity

Preform Permeability Fiber Volume Fraction

Desired Performance & Process Constraints Hsiao ONR Review - 11

Automated Mold Filling Monitoring & Control © 2003 University of Delaware All rights reserved

1 Jul 2003

Case 5: Using SLIC to Characterize the Racetracking (Edge Effect) S3 R 4 S5 R5

R3 S4

S2

S1

Line injection

R2

R1

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.

Hsiao ONR Review - 12

© 2003 University of Delaware All rights reserved

1 Jul 2003

Case 6: Online Flow Monitoring & Control with SLIC Tekscan TM Sensor Area (Pressure Grid Film)

Experimental resin arrival times t0, t1, t2, t3, t4 are all collected IG1 Initial injection gate (IG) with flow runner Fixed vent

AG1 CS2 CS3 CS1 AG2

Disturbance Mode 29 is selected from the Database

Implement the customized control action for Mode 29

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

Auxiliary gate (AG) Successful injection

Disturbance detection sensor (DS) Control action trigger sensor (CS) Hsiao ONR Review - 13

© 2003 University of Delaware All rights reserved

1 Jul 2003

Efforts Towards User-Friendly Software • Develop the MACRO feature which allows SLIC to be run by MACROS (either Defaulted or User Specified). • Seamless interface with Automated RTM Platform on manufacturing floor. MACRO Mesh

Resiii Viscosity

1

' '•

p

Gates/Vents Design

Preform Permeability Fiber Volume Fraction

Instruction 1 Instruction 2 Instruction 3 Instruction 4 Instruction 5 etc.

(Inline Mold Filling Monitoring and Precisely Characterize Fiber Volume Fraction and Permeability

SLIC

9 Layout of Row Runners and Flow Distribution Media

Hsiao ONR Review - 14

$$$ Cost Function & Constraints

Online Mold Filling Control

© 2003 University of Delaware All rights reserved

1 Jul 2003

Summary SLIC • •

:>:>:>/>•>•:•>•:

PREFORM

• RACETRACKING (DISTRUBANCE) RESIN

µ

•

AUTOMATED 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 SLIC

1 0.8 0.6 0.4 0.2 0

• Rapid design for RTM/VARTM. 0

0.02

0.04

α (Τ)

0.06

• Less cost for process development. • Reliable and comprehensive mold filling solution. • Advanced flow monitoring/control technology provides the opportunity to elevate the part quality and reduce the cycle time.

Hsiao ONR Review - 15

© 2003 University of Delaware All rights reserved

1 Jul 2003

Future Work Graphic User Interface (GUI) Documentation • User Manual • Examples • Tutorials

More Available Macros for Users to Choose from

SLIC

Probability Model FASTRAC Flow Control in VARTM Preform Distribution Media

RTM Light Optimization Hsiao ONR Review - 16

© 2003 University of Delaware All rights reserved

1 Jul 2003

Future Work

1 --

s

•

s

_/ ^

f

Y /

~ ~ Online Characterize Preform Compaction Model? Optimize the Distribution Media ? Hsiao ONR Review - 17

© 2003 University of Delaware All rights reserved

1 Jul 2003

Acknowledgements Ø Ø Ø Ø Ø Ø Ø Ø Ø

Professor Suresh G. Advani Ms. Delphine Coatleven Mr. Mathieu Devillard Dr. Ali Gokce Ms. Susanna Laurenzi Dr. Bojan Markicevic Mr. Dhiren Modi Mr. Yeshwanth Rao K. Naveen Dr. Pavel Simacek

Ø Office of Naval Research (ONR) Hsiao ONR Review - 18

© 2003 University of Delaware All rights reserved

1 Jul 2003