Analysis of Spring-in for Composite Plates Using ANSYS Composite Cure Simulation

Abstract

Process induced dimensional changes in composite parts has been the topic of interest for many researchers. The residual stresses that develop in fiber-reinforced laminates during curing process while the laminate is confined to the process tool often leads to dimensional changes such as spring-in of angles and warpage of flat sections. Many experimental studies have put emphasis on this issue and various researches show different methods to predict these dimensional changes. The traditional trial-and-error approach can work for simple geometries, but composite parts with complex shapes require more sophisticated models. When composite laminates are subjected to thermal stresses, such as the heating and cooling processes during curing, they can become distorted as the difference between the in-plane and the through-thickness thermal expansion coefficient, as well as chemical shrinkage of the epoxy, causes the enclosed angle of curved sections and angle components to be reduced. Distorted components can cause problems during assembly, significantly increasing production costs and affecting performance. This paper focuses on predicting these shape deformations using software simulation of composite manufacturing and curing. Various factors such as resin shrinkage, degrees of cure, difference between coefficient of thermal expansion of mold and composite are taken into consideration. A cure kinetic model is presented which illustrates the matrix behavior during cure.