Integrated simulation approach for structural analysis of composite components considering process simulation data

The aim in this study is to include virtual manufacturing process data in the structural finite element analysis on a component level. The main challenge here is to provide an as-built, more realistic structural simulation for carbon fibre reinforced composites with strength and stiffness predictions based on discontinuous data from preceding manufacturing steps such as preforming and liquid composite moulding. This abstract describes the method developed for data conversion through mapping algorithms. Secondly, different approaches to consider shearing effects in stiffness prediction models such as the one of Halpin-Tsai for unidirectional lamina or a one-dimensional undulation model for woven fabrics, are analysed. Hence, an integrated simulation tool chain is defined starting at the preforming stage, in which the actual material orientation and ply thicknesses are retrieved from preforming simulation, and ending with an analysis of the structural behaviour under operational conditions. For demonstrating purposes, a component is developed. The component is made of an aerospace qualified carbon fibre reinforced epoxy. At the end, the impact of this as-built, more realistic structural simulation approach is discussed. This work is supported by the German Federal Ministry of Education and Research (BMBF) through the project MAI Design.