A zone-based approach to predict process-induced distortions of composite structures based on a "spring-in reference curve"

Abstract

Manufacturing of composite structures is inevitably impeded by process-induced distortions. In aerospace industries suppliers are often responsible for making parts according to requirements. Thus, the typical ‘supplier scenario’ is characterized by a strong demand for distortion predictions for sake of tool compensation, in order to make parts conform to given tolerances. However, suppliers simultaneously face a lack of relevant information to derive compensation measures, as neither process-simulation models nor corresponding parameters are accessible. A novel approach is presented within this paper which amalgamates latest experimental results on spring-in distortions in form of a ‘spring-in reference curve’ and an earlier presented phenomenological-numerical simulation concept. This combination leads to a zone-based prediction strategy, focusing on process-induced distortions, which is close to engineering practice and applicable within the typical ‘supplier scenario’.