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ABSTRACT
In this paper a finite element code for modelling of pressure driven
axisymmetric consolidation of composite material from commingled yarns is
presented. The proposed model is developed on the basis of a two-phase continuum
model incorporated in a FE-framework. The applicability of the code to
axisymmetric geometries is demonstrated by analysis of the consolidation, i.e. resin
infiltration and fibre bundle network deformation, of a GF/PP pressure vessel. In
this numerical example two different sets of processing conditions are presented.
Based on these analysis results conclusions on the process ability of the investigated
vessel configuration and manufacturing scheme are drawn and processing
recommendations are given.
INTRODUCTION
Figure 2. Schematic of the assumed phases, a solid phase (white) and a fluid phase (black).
(a) (b)
Figure 3. Schematic of the assumed inter-bundle processes consisting of elastic deformation and
matrix flow between the bundles.
The solid and fluid phases are denoted s and f, respectively. Their volume
fractions n s and n f are defined in terms of the constituents as:
n s ( x, t ) = φ p ( x, t ) + φ v ( x, t ) and n f ( x, t ) = φ l ( x, t ) , (1)
where φ p is the particle volume fraction, φ v the void volume fraction and φ l the
liquid volume fraction. The intrinsic density, associated with each phase, is denoted
ρ α , where α = s, f , whereby, using the indicator function χ α , the bulk density per
unit bulk volume is obtained as
1 α
ρˆ α ( x, t ) = ³
vv
ρ ( x, t ) χ α ( x, t ) dx = nα ( x, t ) ρ α ( x, t ) with α = s, f . (2)
Figure 4. Schematic of the assumed intra-bundle processes consisting, (a) of elastic interaction
between fibres, (b) matrix infiltration into the bundle.
Following the development in [4], it is assumed that each spatial point of the
mixture is simultaneously occupied by particles from the solid and fluid phase.
Upon deformation the continuum phases move via individual non-linear
deformation maps, ϕ s and ϕ f , defined as
( )
x = ϕα Xα ,t , α = s, f , (3)
where x denotes the current position of a continuum particle XĮ at the time t, see
Figure 5.
ϕ s( x, t ) -1
∂) 0
)0:=) s0
s ϕ s⊗∇
∇ Xs ∂)
X x
)
f
ϕ
f
X
(
e = ı : l − p div v d + v d ⋅ ρ f g − ρ f ∇e f − ∇p , ) (8)
where e f represents the internal energy for the fluid phase, l = v ⊗ ∇ X = F ⋅ F −1 is
the spatial velocity gradient and F = ϕ ⊗ ∇ X is the deformation gradient. The
localised form of the entropy inequality for the mixture is now specified as
+ = s + ρ f v d ⋅ ∇s f ≥ 0 . (9)
Moreover, by introducing entropy production in terms of internal energy and
Helmholtz free energy, ψ , the equation (9) transforms to
+ = e − ψ + ρ f v d ⋅ ∇s f ≥ 0 . (10)
Finally, upon combining (10) with (8) and (7) the entropy inequality for the solid-
fluid interaction is obtained as
+ = ı : l − n s pε − ρˆ sψ − h ef ⋅ v d ≥ 0 , (11)
where ı = ı + p 1 is the Terzaghi effective stress and h ef is the effective drag force
defined as h ef = ∇p − ρ f g .
Constitutive models
In this section the formulation of the boundary value problem and the
corresponding finite element formulation for modelling the axisymmetric
consolidation are described. The model is developed considering composite
manufacturing using a press forming process. In the studied process, the component
(in this case a pressure vessel) is subjected to an external uniform pressure sufficient
to drive the infiltration of resin into the bundles. However, the overall pressure
gradients are too weak to drive any significant macroscopic Darcy flow, therefore it
is assumed that +3 ≡ 0 . Thus, the subsequent development is specialised to the
undrained condition.
Assuming undrained conditions implies that both the fluid and solid contents
are conserved. This may be formulated as
1
n f ρ f = ns ρ s = , (14)
J
which, combined with the assumption of incompressible fluid phase, gives a
relationship between the volumetric deformation of the fibre network and the solid
volume fraction, ns, and the compaction strain, ε , as
(
J − 1 − n0s ) ε = − ln § ρ s
· § J − 1 − n0s( ) ·¸ .
¨ s ¸ = ln ¨
s
n = (15)
J © ρ0 ¹ ¨ n0s ¸
© ¹
In order to formulate the finite element solution, the weak form of the
momentum balance for the mixture of solid and fluid phases is written in terms of
the balance between internal virtual work G int and external virtual work G ext
G int − G ext = 0 , (16)
where, omitting the volume loadings, the following expressions are derived
G int = ³ δ l : IJ dV
B0
, (17)
G ext = ³ δϕ ⋅ t ds
∂B
here IJ is the total Kirchhoff stress and t is the prescribed nominal traction vector at
the external boundary defined in terms of applied pressure, p ext , as t = p ext n .
Consequently, pull-back to the reference configuration and definition of total
Kirchhoff stress gives
G int = ³ δ l : ( IJ − J p 1) dV
B0
. (18)
G ext = ³
∂B0
− p extδϕ ⋅ J F − t ⋅ N dS
The linearised weak form of the internal virtual work of the mixture was
derived by Larsson et al. [3] and is expressed for an incompressible fluid as
§ J ·
(
G int = ³ δ l : ¨ E2 + 1 ⊗ IJ − J p 1 ⊗ 1 − 2I sym + K s 1 )
⊗ 1 ¸ : l dV . (19)
B0
¨
© J − 1 − n0
s
¸
¹ ( )
The linearised weak form of the external virtual work of the mixture is obtained via
linearisation of the term J F − t ⋅ N in (18):
D
Dt
( )
J F − t ⋅ N = F − t ⋅ N J + J F − t ⋅ N , (20)
( (
F −t ⋅ N J F −t : F − J F −t ⋅ F t ⋅ F −t ⋅ N = JF − t ⋅ N ⊗ F −t − F −t ⊗ F −t ⋅ N ( ) ) ) : F . (21)
The linearised weak form of the external virtual work of the mixture is finally
obtained as
G ext = ³
∂B0
( ( (
p extδϕ ⋅ JF −t ⋅ N ⊗ 1 − F −t ⊗ F −t ⋅ N ⋅ F t : l dS . )) ) (22)
In the special case of axisymmetry, the momentum balance for the mixture of
solid and fluid phases reads
³ δ l : ( IJ − J p 1) R d Ω − 2π ³ − p δϕ ⋅ J F −t ⋅ NR dL = 0 ,
ext
2π (23)
Ω0 ∂Ω0
A (b
e =1
e − feext ) = 0 , (27)
where the assembly operator A defines to the element global node topology. In (27),
the finite element vectors are defined as
NODE NODE
be = A
I =1
³ ( IJ − J p 1) ⋅ g I R d Ω
Ω0 e
and feext = A ³
I =1 ∂Ω
− p ext N I ⋅ J F − t ⋅ NR dL , (28)
0e
where A defines the internal topology between element variables and the tensorial
quantities, i.e.
NODE NODE
δl: IJ = ¦
I =1
δϕ eI ⋅IJ ⋅ g I = δϕˆ et A IJ ⋅g
I =1
I
. (29)
NODE NODE
K int
e = A A ³g
I =1 J =1 Ω
I
( (
⋅ E 2 + 1 ⊗ IJ − J p 1 ⊗ 1 − 2I sym )
0
( ( ))
+ K s J J − 1 − n0s 1 ⊗ 1 ⋅ g I Rd Ω, ) (31)
NODE NODE
K ext
e = A A ³
I =1 J =1 ∂Ω
0
( ( (
p ext N I JF − t ⋅ N ⊗ 1 − F − t ⊗ F − t ⋅ N ⋅ F t ⋅ g I RdL. )) )
E ζ µ G
Param ks ms kb mb φ0
[GPa] [ȝm] [Pa/s] [MPa]
Value 75 0.0033 15.5 0.0093 15.5 0.685 200 410 5.8
In Table 1, E refers to the Young’s modulus of the fibres and ks and kb are
nondimensional front factors for the fibre bundles and the fibre bundle network
response, respectively. ms and mb are nondimensional exponents used in the fibre
packing equation [3]. φ0 is the fibre volume fraction in the bundles of the reference
configuration (undeformed). Finally, ζ is the material characteristic length of
infiltration, µ is the resin viscosity and G is the shear modulus of the fibre bundle
network.
Numerical Analysis
Figure 6. The vessel geometry represented using the undeformed mesh [m].
Figure 7. The degree of infiltration vs. time for the five selected elements, as defined in (a).
The results from the simulations are presented in Figure 7 and Figure 8.
Figure 7 shows the evolution of the degree of infiltration versus time at the two
pressure levels. Results are presented at five different locations, defined in
Figure 7 a. Figures 7 b and c show the evolution of infiltration at 1 and 8 bars,
respectively.
It is observed that of infiltration at 1 bar is very slow. For instance, the
maximum degree of infiltration at t = 200 [sec] is less than 0.5. An acceptable level
of infiltration, say ξ ≥ 0.7 , is achieved after about 30 minutes (results not shown in
the figure). However, the pressure vessel processed at 8 bar shows significantly
higher rates of infiltration. The region of the neck where the pressure load acts
along the y-axis, i.e. element 14, is fully infiltrated after two minutes. Moreover, at
t = 120 [sec] almost the entire vessel is infiltrated to ξ ≈ 0.6 , one exception being
the inside of the neck, element 22, where the degree of infiltration is ξ ≈ 0.4 .
Finally, considering the results in element 134 it is concluded that its rate of
infiltration is very high during the first 20 seconds, where after it slows down
considerably – never reaching full consolidation. This observation applies for both
load cases, however this phenomenon is most pronounced for the second load case.
Figure 8 shows the deformation as well as the infiltration at the final load-step,
t = 120 [sec], for the 8 bar case. In consistence with the results shown in the
Figure 7 c the degree of infiltration, at the same time step, is both highest and
lowest at the neck of the vessel.
Figure 8. Degree of infiltration and deformation pattern at the final time step.
DISCUSSION AND CONCLUDING REMARKS
REFERENCES