Thick-walled fiber composite components in winding technology - experiment and modeling

纤维增强薄壁部件的缠绕技术代表了一种成熟的制造技术。另一方面，在厚壁组件的情况下，由于所使用的树脂系统的放热固化反应而发生高温，由于所使用的材料的中等导电性，这可能导致组件的损坏。因此，其目的是要有排除此类事件的预测可能性。该问题代表了空间相关各向异性材料性质的化学-热-力学问题。特别是，由于长丝张力，固化和工艺速度的残余应力的预测是进一步的兴趣。为了提供一个预测工具，这里在有限元方法的框架内，需要解决一些基本的研究。这些问题涉及(1)根据交联程度和各向异性对基本材料流变、热学和机械性能的完整表征，(2)缠绕过程中过程的整体计量记录和相关的技术工具实施，(3)旋转制造过程中过程的多物理场耦合建模和相关的固化。(4)开发用于预测残余应力的仿真工具，从而提供工艺优化策略的可能性。首先，所应用的树脂体系和所使用的纤维的特征，使三维材料模型变得适用或可开发。然后，针对内部和外部过程的热和机械记录，开发了缠绕过程中的测量实现。在此基础上，在有限元法的框架下推导了发展、旋转结构的运动学及其相应的平衡方程和相关数值。除了材料模型的开发和模型方程中相关材料参数的识别之外，还将提供验证实验，以便能够对高度复杂行为的预测质量做出陈述。

The winding technique for fiber-reinforced, thin-walled components represents an established manufacturing technology. In the case of thick-walled components, on the other hand, high temperatures occur due to the exothermic curing reaction of the resin systems used, which can lead to damage of the components due to the moderate conductivity of the materials employed. Therefore, the aim is to have prediction possibilities to exclude such events. The problem represents a chemo-thermomechanical problem for spatially dependent anisotropic material properties. In particular, the prediction of residual stresses due to filament tension, curing, and process speed are of further interest. In order to provide a prediction tool, here within the framework of the finite element method, a number of fundamental investigations need to be addressed. These concern (1) the complete characterization of the basic materials with regard to their rheological, thermal and mechanical properties depending on the degree of crosslinking and the anisotropy present, (2) the holistic metrological recording of the processes in the winding process and the associated technical tooling implementation, (3) the multi-physics coupled modeling of the processes during the rotational manufacturing process and the associated curing, and (4) the development of a simulation tool for the prediction of residual stresses and thus the possibility to provide a process optimization strategy. First, the applied resin system and the fibers used are characterized so that a three-dimensional material model becomes applicable or developable. Then, a measurement implementation in the winding process is developed with regard to the thermal and mechanical recording of the internal and external processes. Based on this, the derivation of the kinematics of developing, rotating structures as well as the corresponding balance equations and the associated numerics are derived within the framework of the finite element method. In addition to the material model development and the identification of the associated material parameters of the model equations, validation experiments are then to be provided in order to be able to make statements about the prediction quality of the highly complex behavior.