Development and validation of a virtual process chain for composite structural components considering imperfections with application to a rotor blade component

考虑到应用于转子叶片部件的缺陷，开发和验证复合结构部件的虚拟工艺链

基本信息

批准号：
329147126
负责人：
Professor Dr.-Ing. Axel Herrmann
金额：
--
依托单位：
BIBA - Bremer Institut für Produktion und Logistik GmbH an der Universität Bremen
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/329147126?language=en
关键词：
Development validation virtual process chain

项目摘要

This project aims at reducing the flaws due to manufacturing in composite structural components with the help of simulating the full process chain (manufacturing simulation and structural analysis) and at making the process deviations smaller through a more precise knowledge of the underlying process relations. There is a need for research at this moment since the current knowledge relates to the individual process steps only and because a process simulation through the whole process chain is not available as yet. In this project, establishing a virtual process chain for the manufacturing of composite structural components for a wind turbine rotor blade is defined as a concrete objective. In order to be able to predict the mechanical strength of the structural component, the manufacturing process is represented by a draping and handling simulation and an infusion simulation, and the curing process is included in the structural analysis in an appropriate way. The resulting process parameters related to the actual position of the rovings and the resin saturation can be used in the final step of strength analysis of the composite component manufactured. The influence of flaws due to the manufacturing process on the structural behavior is quantified with appropriate Finite Element models in systematic, numerical investigations. Probabilistic analyses in all phases of the process simulation, in which the statistical distribution of imperfections are considered, provide the corresponding scatter of the structural properties. The analysis of the complete process chain - manufacturing simulation and structural analysis - makes it possible to simulate the influence of production related imperfections on the structural behavior and to specify flaw tolerances connected with the manufacturing process. This is achieved in particular through the new approach presented, in which the most relevant imperfections (e.g. geometrical deviations or scatter of material properties) are included at different modeling levels. For this aim, the composite material is analyzed in detail at three levels, the micro-scale (single fiber), the meso-scale (roving) and the macro-scale (roving-composite). On the basis of the results of the simulation of the complete process chain, criteria and design rules for flaw tolerances - flaws which in the manufacturing process of a typical, relevant structural component can be considered as acceptable - can be established, and thereby the product scrap rate can be reduced and certification processes can be facilitated.

该项目旨在借助模拟完整的过程链（制造模拟和结构分析）来减少由于复合结构组件制造而引起的缺陷，并通过对基础过程关系的更精确的了解使过程偏差更小。目前需要进行研究，因为当前知识仅与单个过程步骤有关，并且由于尚不可用的整个过程链中的过程模拟。在这个项目中，建立一个虚拟工艺链，用于制造风力涡轮转子叶片的复合结构组件，定义为具体目标。为了能够预测结构组件的机械强度，制造过程由悬垂和处理模拟和输注模拟表示，并以适当的方式包括固化过程。与Rovings的实际位置和树脂饱和度有关的结果过程参数可以在制造的复合组件的强度分析的最后一步中使用。在系统的数值研究中，通过适当的有限元模型来量化由于制造过程对结构行为的缺陷的影响。在考虑不完美的统计分布的过程模拟的所有阶段，概率分析提供了结构特性的相应散射。对完整过程链的分析 - 制造模拟和结构分析 - 可以模拟与生产相关的缺陷对结构行为的影响，并指定与制造过程相关的缺陷公差。这是通过提出的新方法来实现的，其中最相关的缺陷（例如，材料特性的几何偏差或散布）在不同的建模水平上包括在内。为此，对复合材料进行了三个级别的详细分析，即微尺度（单光纤），中尺度（Roving）和宏观尺度（Roving-Composite）。基于完整过程链的仿真结果，缺陷公差的标准和设计规则 - 在典型的，相关的结构组件的制造过程中，可以将其视为可接受的缺陷，从而可以降低产品废料速率，并可以降低认证过程。