Surface quality prediction of thermoset composite structures using geometric simulation tools

Abstract

The surface quality of polymer composite laminates was examined via geometric modelling techniques and compared to experimental data. TexGen software provided the platform for the development of a surface roughness simulation tool which accounted for textile architecture and specific cure kinetics of the matrix. The study focused on the influence of thermal and chemical shrinkage during cure and the change in localised volume fraction across the surface of a unit cell. A one-dimensional analysis was used to determine proportional dimensional changes to the matrix region, with the results stitched together to form a three-dimensional topological plot. Three demonstrator geometric models were developed to represent a carbon 2 × 2 twill weave fabric with 3000, 6000 or 12 000 tows. These models were analysed with low and high shrink resin properties. Optical microscopy was used to determine accurate tow forms for compacted tows which aided the development of the geometric model. Simulated profiles, topography and surface roughness measures were compared to experimental data which demonstrated the significance of matrix contraction and fabric architecture on the final surface quality. The simulations were shown to represent experimental data typically within 6%.