Integrating Computer Aided Curing Of Composites with Advanced Tooling Concepts

Composite parts and the tooling they are fabricated on deform during processing due to the thermal expansion behavior of materials and the cure kinetics of thermosetting polymers. This behavior is very complex and can result in parts with significant residual stress that may affect part removal, part fit-up, and overall performance. The objective of this program is to develop a CAD/CAM system that can be employed to define an optimized processing cycle and a tool design that will minimize process induced residual stresses in composite laminates. This is achieved by implementing a composite cure model that describes the component behavior during processing and through numerical iteration, defines a process cycle that results in minimal process induced stress. This information is then employed in designing a tool that matches the thermal expansion behavior of the composite laminate. Therefore, no thermo-mechanically induced stresses will be created in the composite during processing. The output of the CAD/CAM system will be an optimized processing cycle for the composite laminate and all the required design information to produce the matching tool.