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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.
In the friction tests between honeycomb with film adhesive and prepreg, the relative displacement occurs between the film adhesive and the prepreg. The film adhesive does not shift relative to the honeycomb. This is consistent with the core crush behavior where the honeycomb moves together with the film adhesive, as can be seen in Figure 2(a). The pull-through forces of the friction measurements between honeycomb and prepreg at 1 mm deformation are plotted in Figure 17(a). While the friction at 100°C is similar to the friction at 120°C, it decreases significantly at 130°C and exhibits a minimum at 140°C. At 150°C, the friction rises again slightly and then sharply at 160°C. Since the viscosity of the M18/1 prepreg resin drops significantly before it cures [23], the minimum friction at 140°C could result from a minimum viscosity of the mixture of prepreg resin and film adhesive before the bond subsequently cures. Figure 17(b) shows the mean value curve of the friction measurements at 140°C. The error bars, which represent the standard deviation, reveal the good repeatability of the tests. The force curve is approximately horizontal between 1 mm and 2 mm. The friction then slightly rises. As with interlaminar friction measurements, this could be due to the fact that resin is removed by friction and the proportion of boundary lubrication increases. Figure 18 shows the surfaces after the friction measurement. The honeycomb cell walls are clearly visible in the film adhesive. There are areas where the film adhesive is completely removed and the carrier material of the film adhesive becomes visible. In addition, the viscosity of the resin changes as the curing progresses during the friction test. This can also affect the force-displacement curve.
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.
Rehabilitative body weight supported gait training aims at restoring walking function as a key element in activities of daily living. Studies demonstrated reductions in muscle and joint forces, while kinematic gait patterns appear to be preserved with up to 30% weight support. However, the influence of body weight support on muscle architecture, with respect to fascicle and series elastic element behavior is unknown, despite this having potential clinical implications for gait retraining. Eight males (31.9 ± 4.7 years) walked at 75% of the speed at which they typically transition to running, with 0% and 30% body weight support on a lower-body positive pressure treadmill. Gastrocnemius medialis fascicle lengths and pennation angles were measured via ultrasonography. Additionally, joint kinematics were analyzed to determine gastrocnemius medialis muscle–tendon unit lengths, consisting of the muscle's contractile and series elastic elements. Series elastic element length was assessed using a muscle–tendon unit model. Depending on whether data were normally distributed, a paired t-test or Wilcoxon signed rank test was performed to determine if body weight supported walking had any effects on joint kinematics and fascicle–series elastic element behavior. Walking with 30% body weight support had no statistically significant effect on joint kinematics and peak series elastic element length. Furthermore, at the time when peak series elastic element length was achieved, and on average across the entire stance phase, muscle–tendon unit length, fascicle length, pennation angle, and fascicle velocity were unchanged with respect to body weight support. In accordance with unchanged gait kinematics, preservation of fascicle–series elastic element behavior was observed during walking with 30% body weight support, which suggests transferability of gait patterns to subsequent unsupported walking.