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.

该项目旨在通过模拟整个工艺链（制造模拟和结构分析）来减少复合材料结构部件制造中的缺陷，并通过更精确地了解底层工艺关系来缩小工艺偏差。目前需要进行研究，因为当前的知识仅涉及各个工艺步骤，并且还无法进行整个工艺链的工艺模拟。在该项目中，具体目标是建立风力涡轮机转子叶片复合结构部件制造的虚拟工艺链。为了能够预测结构部件的机械强度，制造过程通过悬垂和处理模拟以及灌注模拟来表示，并且固化过程以适当的方式包含在结构分析中。与粗纱的实际位置和树脂饱和度相关的所得工艺参数可用于所制造的复合材料部件的强度分析的最后步骤。在系统的数值研究中，通过适当的有限元模型来量化制造过程中的缺陷对结构行为的影响。过程模拟的所有阶段中的概率分析（其中考虑缺陷的统计分布）提供了结构特性的相应散布。通过对整个工艺链的分析（制造模拟和结构分析），可以模拟生产相关缺陷对结构行为的影响，并指定与制造工艺相关的缺陷公差。这尤其是通过所提出的新方法来实现的，其中最相关的缺陷（例如几何偏差或材料属性的分散）包含在不同的建模级别中。为此，我们在微观尺度（单纤维）、细观尺度（粗纱）和宏观尺度（粗纱复合材料）三个层面对复合材料进行了详细分析。根据整个工艺链的模拟结果，可以建立缺陷容差的标准和设计规则（典型的相关结构部件的制造过程中的缺陷可以被认为是可接受的），从而可以制定产品可以降低废品率并简化认证流程。