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Development and validation of a virtual process chain for composite structural components considering imperfections with application to a rotor blade component

考虑到应用于转子叶片部件的缺陷，开发和验证复合结构部件的虚拟工艺链

基本信息

批准号：
329147126
负责人：
Professor Dr.-Ing. Axel Herrmann
金额：
--
依托单位：
BIBA - Bremer Institut für Produktion und Logistik GmbH an der Universität Bremen
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/329147126?language=en
关键词：
Development validation virtual process chain

项目摘要

This project aims at reducing the flaws due to manufacturing in composite structural components with the help of simulating the full process chain (manufacturing simulation and structural analysis) and at making the process deviations smaller through a more precise knowledge of the underlying process relations. There is a need for research at this moment since the current knowledge relates to the individual process steps only and because a process simulation through the whole process chain is not available as yet. In this project, establishing a virtual process chain for the manufacturing of composite structural components for a wind turbine rotor blade is defined as a concrete objective. In order to be able to predict the mechanical strength of the structural component, the manufacturing process is represented by a draping and handling simulation and an infusion simulation, and the curing process is included in the structural analysis in an appropriate way. The resulting process parameters related to the actual position of the rovings and the resin saturation can be used in the final step of strength analysis of the composite component manufactured. The influence of flaws due to the manufacturing process on the structural behavior is quantified with appropriate Finite Element models in systematic, numerical investigations. Probabilistic analyses in all phases of the process simulation, in which the statistical distribution of imperfections are considered, provide the corresponding scatter of the structural properties. The analysis of the complete process chain - manufacturing simulation and structural analysis - makes it possible to simulate the influence of production related imperfections on the structural behavior and to specify flaw tolerances connected with the manufacturing process. This is achieved in particular through the new approach presented, in which the most relevant imperfections (e.g. geometrical deviations or scatter of material properties) are included at different modeling levels. For this aim, the composite material is analyzed in detail at three levels, the micro-scale (single fiber), the meso-scale (roving) and the macro-scale (roving-composite). On the basis of the results of the simulation of the complete process chain, criteria and design rules for flaw tolerances - flaws which in the manufacturing process of a typical, relevant structural component can be considered as acceptable - can be established, and thereby the product scrap rate can be reduced and certification processes can be facilitated.

该项目旨在通过模拟整个工艺链（制造模拟和结构分析）来减少复合材料结构部件制造过程中的缺陷，并通过更精确地了解基本工艺关系来减小工艺偏差。目前有必要进行研究，因为目前的知识只涉及单个工艺步骤，而且还没有通过整个工艺链进行工艺模拟。在本项目中，为风力涡轮机转子叶片的复合材料结构部件的制造建立虚拟工艺链被定义为具体目标。为了能够预测结构部件的机械强度，制造过程由覆盖和处理模拟以及灌注模拟表示，并且固化过程以适当的方式包括在结构分析中。与粗纱的实际位置和树脂饱和度相关的所得工艺参数可用于所制造的复合部件的强度分析的最后步骤。在系统的数值研究中，通过适当的有限元模型量化了制造过程中缺陷对结构性能的影响。在过程模拟的所有阶段中的概率分析，其中考虑了缺陷的统计分布，提供了相应的结构特性的分散。对完整工艺链的分析--制造模拟和结构分析--使得模拟与生产相关的缺陷对结构行为的影响并指定与制造过程相关的缺陷公差成为可能。这是通过提出的新方法来实现的，其中最相关的缺陷（例如几何偏差或材料特性的分散）被包括在不同的建模级别。为此，复合材料在三个层次上进行了详细分析，微观尺度（单纤维），介观尺度（粗纱）和宏观尺度（粗纱复合材料）。基于完整工艺链的模拟结果，可以建立缺陷容限的标准和设计规则-在典型的相关结构部件的制造过程中可以被认为是可接受的缺陷，从而可以降低产品报废率并简化认证过程。