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

Liebisch, Martin und Hein, Robert und 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. (nicht veröffentlicht)

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Kurzfassung

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.

elib-URL des Eintrags:https://elib.dlr.de/108419/
Dokumentart:Konferenzbeitrag (Vortrag)
Titel:PROBABILISTIC PROCESS SIMULATION TO PREDICT PROCESS INDUCED DISTORTIONS AND STRESSES OF A COMPOSITE FRAME
Autoren:
AutorenInstitution oder E-Mail-AdresseAutoren-ORCID-iDORCID Put Code
Liebisch, Martinmartin.liebisch (at) dlr.deNICHT SPEZIFIZIERTNICHT SPEZIFIZIERT
Hein, Robertrobert.hein (at) dlr.deNICHT SPEZIFIZIERTNICHT SPEZIFIZIERT
Wille, Tobiastobias.wille (at) dlr.deNICHT SPEZIFIZIERTNICHT SPEZIFIZIERT
Datum:September 2016
Referierte Publikation:Ja
Open Access:Nein
Gold Open Access:Nein
In SCOPUS:Nein
In ISI Web of Science:Nein
Status:nicht veröffentlicht
Stichwörter:Process Simulation, Process induced distortions, Residual stresses, Material uncertainty, Manufacturing scatter, Probabilistic process simulation, Surrogate models
Veranstaltungstitel:Deutscher Luft- und Raumfahrtkogress (DLRK) 2016
Veranstaltungsort:Braunschweig
Veranstaltungsart:nationale Konferenz
Veranstaltungsdatum:13.-15. September 2016
HGF - Forschungsbereich:Luftfahrt, Raumfahrt und Verkehr
HGF - Programm:Luftfahrt
HGF - Programmthema:Flugzeuge
DLR - Schwerpunkt:Luftfahrt
DLR - Forschungsgebiet:L AR - Aircraft Research
DLR - Teilgebiet (Projekt, Vorhaben):L - Simulation und Validierung (alt)
Standort: Braunschweig
Institute & Einrichtungen:Institut für Faserverbundleichtbau und Adaptronik > Strukturmechanik
Hinterlegt von: Liebisch, Martin
Hinterlegt am:05 Dez 2016 10:02
Letzte Änderung:20 Jun 2021 15:48

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