Thickness variation in contoured composite parts by vacuum infusion

Abstract

Contoured laminates were produced by vacuum infusion (VI), and thickness variations were monitored dynamically as a function of process parameters. Process simulations were performed using finite element software (PAM-RTM), and predictions of thickness along the length of the laminate were compared with dynamic measurements. Initial simulations approximated the effects of corners on preform deformation and fabric draping behavior. Subsequent modifications to the simulation geometry and material properties were implemented to increase accuracy and more closely match experimental measurements. User-defined geometry (UDG) simulations were used to predict both the maximum corner deviation and the area of corner deviation with greater accuracy. The present study demonstrates a workflow for use of analytical tools to design and control vacuum infusion processes. The workflow leverages process monitoring and modified process simulation tools to provide insight into parametric effects and to guide process modifications to reduce product variability.

Graphical Abstract

Keywords:

• Vacuum infusion
• thickness deviation
• contoured laminates
• finite element analysis

Acknowledgements

The authors acknowledge undergraduate research assistants Ryan Kraemer and Ashiwini Balaganesh for their support in performing experiments. ESI is gratefully acknowledged for continuous support in our use of vacuum infusion simulation software.

Disclosure statement

No potential conflict of interest was reported by the authors.

Data availability statement

The authors confirm that the data supporting the findings of this study are available within the article.