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Probabilistic Process Simulation and In-Situ Process Prediction during Composite Manufacturing as Contribution to Industry 4.0

Hein, Robert and Wille, Tobias and Liebisch, Martin (2019) Probabilistic Process Simulation and In-Situ Process Prediction during Composite Manufacturing as Contribution to Industry 4.0. Nafems World Congress 2019, 17.06.-20.06.2019, Quebec City (Kanada).

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Abstract

In contrast to metallic parts the final geometry and superior structural properties of composite structures evolve during the manufacturing process itself. Thus, the process parameters and process boundary conditions have a significant influence on the final component properties. To ensure a high component quality narrow tolerances during the entire component development process are currently defined. Yet, due to manufacturing-induced deformations as well as material uncertainties and varying process conditions the required geometric tolerances cannot be met in all cases. In case of unauthorized process or part deviations additional time-consuming and costly assessment processes are initiated in present industrial environment. In order to develop new manufacturing processes more efficiently an enhanced simulation strategy for a priori and in-situ prediction of manufacturing-induced deformations and residual stresses of composite structures is developed. Within a sequential temperature-displacement finite element analysis strategy an anisotropic viscoelastic material model is applied to consider temperature and time dependent relaxation effects. In order to take into account fluctuations in process and material parameters the deterministic process simulation is extended by a probabilistic process simulation. For this, fast and efficient surrogate models are derived in order to perform probabilistic simulations in acceptable time. This enables to evaluate the robustness of different curing processes. Furthermore, the derived surrogate models allow for predicting the in-situ properties of components as full 3D field information. For instance, structural properties, such as residual stresses, deformations or stiffness as well as thermal hot-spots and thermo-chemical properties such as degree of cure and glass transition temperature are calculated in real time. In context of Industry 4.0, this enables to evaluate the process and component quality during manufacturing and, therewith, results in an improved process control and enhanced quality management. The method is demonstrated for an automotive car suspension blade.

Item URL in elib:https://elib.dlr.de/130811/
Document Type:Conference or Workshop Item (Speech)
Title:Probabilistic Process Simulation and In-Situ Process Prediction during Composite Manufacturing as Contribution to Industry 4.0
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Hein, RobertRobert.Hein (at) dlr.dehttps://orcid.org/0000-0002-6258-3673
Wille, TobiasTobias.Wille (at) dlr.deUNSPECIFIED
Liebisch, MartinMartin.Liebisch (at) dlr.deUNSPECIFIED
Date:17 June 2019
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:Process simulation, probabilistic, process-induced dedormations, residual stresses, reaction kinetic, industry 4.0
Event Title:Nafems World Congress 2019
Event Location:Quebec City (Kanada)
Event Type:international Conference
Event Dates:17.06.-20.06.2019
Organizer:NAFEMS
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
Deposited By: Hein, Robert
Deposited On:25 Nov 2019 23:50
Last Modified:25 Nov 2019 23:50

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