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Abstract

Process modelling of thermoset matrix composites is typically divided into two distinct and sequential steps: (i) flow-compaction analysis before gelation of the resin when it behaves in a fluid-like manner, and (ii) thermomechanical analysis after gelation when appreciable modulus and thereby stress development occurs. This two-part paper presents a novel approach to integrate the simulation of resin flow and stress development seamlessly during the processing of composites. Part I lays the theoretical foundation for the simpler case of isotropic materials while Part II extends the methodology to the case of transversely isotropic materials. The formulation is implemented in a 2D plane strain finite element code written in MATLAB. Relevant numerical examples are presented to demonstrate both aspects of flow-compaction and stress development throughout the curing process of thermoset matrix composite materials. The effects of resin flow on the development and the final values of residual stresses are investigated.

Keywords

Thermoset matrix composites resin flow residual stress process modelling

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Integration of resin flow and stress development in process modelling of composites: Part I – Isotropic formulation

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