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Layup sequence is directly related to stiffness and deformation resistance of the composite space mirror, and error caused by layup sequence can affect the surface precision of composite mirrors evidently. Variation of layup sequence with the same total thickness of composite space mirror changes surface form of the composite mirror, which is the focus of our study. In our research, the influence of varied quasi-isotropic stacking sequences and random angular deviation on the surface accuracy of composite space mirrors was investigated through finite element analyses (FEA). We established a simulation model for the studied concave mirror with 500 mm diameter, essential factors of layup sequences and random angular deviations on different plies were discussed. Five guiding findings were described in this study. Increasing total plies, optimizing stacking sequence and keeping consistency of ply alignment in ply placement are effective to improve surface accuracy of composite mirror.

Composite space mirror can completely replicate the high-precision surface of mould by replication process, but the actual surface accuracy of the replication composite mirror always decreases. Lamina thickness of prepreg affects the layers and layup sequence of composite space mirror, and which would affect surface accuracy of space mirror. In our research, two groups of contrasting cases through finite element analyses (FEA) and comparative experiments were studied; the effect of different lamina thicknesses of prepreg and corresponding lay-up sequences was focused as well. We describe a special analysis model, validated process and result analysis. The simulated and measured surface figures both get the same conclusion. Reducing lamina thickness of prepreg used in replicating composite space mirror is propitious to optimal design of layup sequence for fabricating composite mirror, and could improve its surface accuracy.

Carbon fiber reinforced polymer, CFRP, composite materials have been used to fabricate space mirror. Usually the composite space mirror can completely replicate the high-precision surface of mould by replication process, but the actual surface accuracy of replicated space mirror is always reduced, still needed further study. We emphatically studied the error caused by layup and curing on the surface accuracy of space mirror through comparative experiments and analyses, the layup and curing influence factors include curing temperature, cooling rate of curing, method of prepreg lay-up, and area weight of fiber. Focusing on the four factors, we analyzed the error influence rule and put forward corresponding control measures to improve the surface figure of space mirror. For comparative analysis, six CFRP composite mirrors were fabricated and surface profile of mirrors were measured. Four guiding control measures were described here. Curing process of composite space mirror is our next focus.

In present study, the optimization injection processes for manufacturing the composite pipe key-part and K/T type joints in vacuum-assisted resin transfer molding (VARTM) were determined by estimating the filling time and flow front shape of four kinds of injection methods. Validity of the determined process was proved with the results of a scaling-down composite pipe key-part containing of the carbon fiber four axial fabrics and a steel core with a complex surface. In addition, an expanded-size composite pipe part was also produced to further estimate the effective of the determined injection process. Moreover, the resin injection method for producing the K/T type joints via VARTM was also optimized with the simulation method, and then manufactured on a special integrated mould by the determined injection process. The flow front pattern and filling time of the experiments show good agreement with that from simulation. Cross-section images of the cured composite pipe and K/T type joints parts prove the validity of the optimized injection process, which verify the efficiency of simulation method in obtaining a suitable injection process of VARTM.

It is widely acknowledged that decisions made in the early design stages have a greater influence on the final product than those made in the later stages. In a conventional design process, composite products are designed without sufficient consideration being given to limitations of composite manufacturing process. Quite often some of composite designs cannot be produced with special performance requirement or cannot be produced at a reasonable cost. To resolve this drawback and achieve the competitive designs for composite product, an integrated knowledge framework that supports the quantitative manufacturability evaluation of composite design proposals was introduced. The essential concept of the composite manufacturability was defined through an in-depth analysis of composite manufacturing process. The evaluation flow was acquired according to the hierarchical indices. A stage-based quality assessment model for the composite multistage process was mainly studies. It relies on the consideration that the final quality of a composite product is mainly determined by some critical stages during a production cycle. Finally, the method is illustrated through a case focusing on the quality issue of void formation in autoclave process.