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A new method for improved autoclave loading within the restrictive framework of helicopter manufacturing is proposed. It is derived from experimental and numerical studies of the curing process and aims at optimizing tooling positions in the autoclave for fast and homogeneous heat-up. The mold positioning is based on two sets of information. The thermal properties of the molds, which can be determined via semi-empirical thermal simulation. The second information is a previously determined distribution of heat transfer coefficients inside the autoclave. Finally, an experimental proof of concept is performed to show a cycle time reduction of up to 31% using the proposed methodology.
Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2015)
Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2019)
Manufacturing process simulation enables the evaluation and improvement of autoclave mold concepts early in the design phase. To achieve a high part quality at low cycle times, the thermal behavior of the autoclave mold can be investigated by means of simulations. Most challenging for such a simulation is the generation of necessary boundary conditions. Heat-up and temperature distribution in an autoclave mold are governed by flow phenomena, tooling material and shape, position within the autoclave, and the chosen autoclave cycle. This paper identifies and summarizes the most important factors influencing mold heat-up and how they can be introduced into a thermal simulation. Thermal measurements are used to quantify the impact of the various parameters. Finally, the gained knowledge is applied to develop a semi-empirical approach for boundary condition estimation that enables a simple and fast thermal simulation of the autoclave curing process with reasonably high accuracy for tooling optimization.