Fiber-Reinforced Polymer Composite Materials in Aerospace Industries

Industry Challenges

Fiber-reinforced polymer (FRP) composite materials have been largely used in the aerospace industry due to their properties such as lightweight, high stiffness, and high strength. In this competitive industry, the potential to optimize the molding process turns out to be an absolute advantage.

Moldex3D Solutions and Benefits

Moldex3D solutions, based on true 3D simulation technology, have the ability to offer robust simulation results for aerospace manufacturers and design engineers to eliminate the prospective challenges and find out ideal process conditions at an early stage. Moldex3D offers robust tools such as Moldex3D Fiber for predicting discontinuous fiber process. Apart from simulating fiber length (fiber breakage prediction), fiber orientation, and fiber concentration, it can also evaluate process-induced anisotropic thermo-mechanical properties. In the case of continuous fiber manufacturing process, Moldex3D RTM has the potential to predict resin-filling behavior in a complex layup. Moldex3D solutions provide the advantages of economic development by reducing time-to-market cycle and saving production cost.

Moldex3D Solves Tough Problems

Fiber Properties

Moldex3D Solves Tough Problems

Challenges

Manufacturers often focus more on fiber length, orientation, and concentration since these properties have a higher effect on the mechanical properties of the product. Fiber breakage could occur inside the cavity and barrel at the filling stage during the injection molding process. Therefore, it is critical to maintaining the fiber length at the time of the injection molding process.

Solutions

Moldex3D has the ability to predict fiber length, orientation, and concentration. Moldex3D simulations could be advantageous to the FRP composites manufacturing process. Moldex3D supports these novel molding technologies as Solution Add-ons.

Anisotropic Filling Behavior

Anisotropic Filling Behavior

Challenges

Product defects such as dry spot caused by unsuitable process conditions are a common problem in the RTM process. It is not easy to predict and control the filling behavior of the resin flow since the face sheet material permeability and the anisotropic property of fabric are very different from that of the core material.

Flow front time at the end of filling stage of the sandwich structure design for a wind turbine blade

Flow front time at the end of filling stage of the sandwich structure design for a wind turbine blade

Solutions

Employing a sophisticated 3D simulation will include various flow parameters in all dimensions and it would be possible to visualize the flow behavior in the mold, thereby further improving and optimizing the RTM process.

Filling behaviors caused by anisotropic permeability along the thickness directions

Filling behaviors caused by anisotropic permeability along the thickness directions

This information has been sourced, reviewed and adapted from materials provided by Moldex3D.

For more information on this source, please visit Moldex3D.

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