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PROBABILISTIC PROCESS SIMULATION TO PREDICT PROCESS INDUCED DISTORTIONS AND STRESSES OF A COMPOSITE FRAME

Liebisch, Martin and Hein, Robert and Wille, Tobias (2016) PROBABILISTIC PROCESS SIMULATION TO PREDICT PROCESS INDUCED DISTORTIONS AND STRESSES OF A COMPOSITE FRAME. Deutscher Luft- und Raumfahrtkogress (DLRK) 2016, 13.-15. September 2016, Braunschweig. (Unpublished)

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Abstract

Within this work, an enhanced simulation strategy for predicting process-induced distortions and residual stresses of composite structures is developed, while taking into account probabilistic variations. The simulation strategy is demonstrated for a carbon fibre reinforced frame of an aircraft fuselage. Based on a sequentially coupled temperature-displacement analysis temperature and degree of cure distributions as well as stresses, strains and distortions are determined. For the description of the reaction kinetic a phenomenological based model considering chemical and diffusion-controlled reactions is introduced. The mechanical material behavior is described by a viscoelastic material model depending on temperature, time and degree of cure. Corresponding process-induced distortions and occurring residual stresses are calculated and analyzed. The results of the process-induced distortions are used to derive a compensated tooling design. In order to analyze the effect of statistical and systematic deviations of underlying process and material parameters a procedure for a probabilistic process simulation is created. Based on a first sensitivity analysis a design of experiment is performed over a specified parameter range. From this surrogate models are derived to enable a full but efficient probabilistic analysis of spring-in angles and residual stresses at multiple frame positions. The effect of process parameter variations and fluctuation of inherent material properties on process-induced distortions is assessed. Moreover, the influence of different process cycles is shown. This allows to determine the expected range of the final part distortion and to derive the resulting tolerances during assembly. For validation of the probabilistic process simulation several frames are manufactured at different process conditions, and frame geometries are measured by digital image correlation technique. The resulting part thicknesses, spring-in angles and global frame distortions are determined. Finally, a comparison of measurements and probabilistic predictions is given, and results are evaluated with respect to main sensitivities.

Item URL in elib:https://elib.dlr.de/108419/
Document Type:Conference or Workshop Item (Speech)
Title:PROBABILISTIC PROCESS SIMULATION TO PREDICT PROCESS INDUCED DISTORTIONS AND STRESSES OF A COMPOSITE FRAME
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Liebisch, Martinmartin.liebisch (at) dlr.deUNSPECIFIED
Hein, Robertrobert.hein (at) dlr.deUNSPECIFIED
Wille, Tobiastobias.wille (at) dlr.deUNSPECIFIED
Date:September 2016
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Unpublished
Keywords:Process Simulation, Process induced distortions, Residual stresses, Material uncertainty, Manufacturing scatter, Probabilistic process simulation, Surrogate models
Event Title:Deutscher Luft- und Raumfahrtkogress (DLRK) 2016
Event Location:Braunschweig
Event Type:national Conference
Event Dates:13.-15. September 2016
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Simulation and Validation
Location: Braunschweig
Institutes and Institutions:Institute of Composite Structures and Adaptive Systems > Structural Mechanics
Deposited By: Liebisch, Martin
Deposited On:05 Dec 2016 10:02
Last Modified:05 Dec 2016 10:02

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