Numerical Simulation Based Process Window for Consolidation of Thermoset Composite Laminates

Abstract

Laminate consolidation is greatly important for continuous fibre reinforced thermoset resin matrix composites and the degree of consolidation depends on resin rheological behaviour and processing conditions. This study focused on the rheological characteristics of two kinds of epoxy resins and a bismaleimide resin and developed an evaluating method based on numerical simulation, providing guidelines to ensure consolidation. The rheological characteristics at isothermal conditions were discussed and the determination of gel point using viscosity increment rate was adopted. Autoclave process for T700S carbon fibre composite laminates was simulated numerically and the effects of cure cycle, number of plies and lay-up type of fibre bed on consolidation were analysed. A process window was constructed to achieve the required degree of consolidation by adjusting the external pressure and the time of applying external pressure. The results show that the quantitative impacts of processing conditions on consolidation and the feasibility of processing operations can be obtained from the established process window.