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Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

Technologies for automated fibre lay-up have proven their usefulness in composites manufacturing. Further development of the technologies, such as Automated Dry Fibre Placement (ADFP), allow further reduction of waste and increase of the design space through tow steering which enables creation of composites with tailored properties. Tow steering is, however, limited by possible defects such as wrinkles which result from mismatch of fibre length and steering path. This paper addresses wrinkle formation at different steering radii and provides a closed-form solution for the problem. Experimental results are used for estimation of the model parameters and validation of the model. An analytical framework is used to explore effects of processing parameters on defect formation. It was found that the tack stiffness has the greatest influence on defect formation. Parametric studies showed that increase of the temperature within the admissible temperature window can improve the tack properties and hence improve the lay-up.

Finite element simulation with cohesive contact is presented, to correlate the vacuum assisted RTM process and the bending performance of Omega beams. The model considers the process induced variations, including part thickness, resin rich pockets and voids. The bending performance prediction relies on cohesive contact to model delamination initiation and propagation. Computing efficiency is achieved by mesh scaling. The modelling approach applies to three variations of Omega beams with the different mode-mixture ratios. The finite element predictions result in a high degree of agreement with the experimental measurements.

A recently developed peel test designed to simulate the automated tape lay-up (ATL) process was used to measure tack and dynamic stiffness of newly developed ATL prepregs. Resin was extracted from the prepreg process before impregnation of the fibres. Isothermal small amplitude frequency sweeps were carried out in shear rheology to determine time–temperature superposition parameters in the form of Williams–Landel–Ferry equation. Gel permeation chromatography and differential scanning calorimetry demonstrated that the resin was not significantly changed during the prepregging process. The WLF parameters were used to transpose isothermal tack and dynamic stiffness results with excellent agreement found. This relationship offers manufacturers using composite prepreg a method to maximise and maintain tack levels at different feed rates by appropriate changes in temperature. This is of significant importance in improving the reliability of automated composite lay-up processes such as AFP and ATL, whose feed rate must vary to accommodate lay-up operations.

Resin chemical shrinkage dictates the surface integrity and the roughness of a composite structure. Thus, to minimize surface failures and to produce a good surface quality it is a requisite to be able to measure and track resin shrinkage during the cure process. This manuscript investigates and evaluates the measuring and monitoring of real-time resin shrinkage using a rheometer, a helium-based pycnometer and a thermo-mechanical analyzer (TMA) for ambient curing UP and epoxy resins. Shrinkage readings obtained from the newly developed robust technique with the rheometer concur well with readings from the traditional pycnometric method. They also coincide within the accepted literature values of 7–10% and 3.5–4.5% for the UP and epoxy systems, respectively. Shrinkage measurements during post-cure were effectively carried out at an elevated temperature, suggesting that the methodology provided can be applied to non-ambient curing systems. The TMA was found to be unsuccessful in measuring shrinkage reliably.

Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

Technologies for automated fibre lay-up have proven their usefulness in composites manufacturing. Further development of the technologies, such as Automated Dry Fibre Placement (ADFP), allow further reduction of waste and increase of the design space through tow steering which enables creation of composites with tailored properties. Tow steering is, however, limited by possible defects such as wrinkles which result from mismatch of fibre length and steering path. This paper addresses wrinkle formation at different steering radii and provides a closed-form solution for the problem. Experimental results are used for estimation of the model parameters and validation of the model. An analytical framework is used to explore effects of processing parameters on defect formation. It was found that the tack stiffness has the greatest influence on defect formation. Parametric studies showed that increase of the temperature within the admissible temperature window can improve the tack properties and hence improve the lay-up.

Finite element simulation with cohesive contact is presented, to correlate the vacuum assisted RTM process and the bending performance of Omega beams. The model considers the process induced variations, including part thickness, resin rich pockets and voids. The bending performance prediction relies on cohesive contact to model delamination initiation and propagation. Computing efficiency is achieved by mesh scaling. The modelling approach applies to three variations of Omega beams with the different mode-mixture ratios. The finite element predictions result in a high degree of agreement with the experimental measurements.

A recently developed peel test designed to simulate the automated tape lay-up (ATL) process was used to measure tack and dynamic stiffness of newly developed ATL prepregs. Resin was extracted from the prepreg process before impregnation of the fibres. Isothermal small amplitude frequency sweeps were carried out in shear rheology to determine time–temperature superposition parameters in the form of Williams–Landel–Ferry equation. Gel permeation chromatography and differential scanning calorimetry demonstrated that the resin was not significantly changed during the prepregging process. The WLF parameters were used to transpose isothermal tack and dynamic stiffness results with excellent agreement found. This relationship offers manufacturers using composite prepreg a method to maximise and maintain tack levels at different feed rates by appropriate changes in temperature. This is of significant importance in improving the reliability of automated composite lay-up processes such as AFP and ATL, whose feed rate must vary to accommodate lay-up operations.

Resin chemical shrinkage dictates the surface integrity and the roughness of a composite structure. Thus, to minimize surface failures and to produce a good surface quality it is a requisite to be able to measure and track resin shrinkage during the cure process. This manuscript investigates and evaluates the measuring and monitoring of real-time resin shrinkage using a rheometer, a helium-based pycnometer and a thermo-mechanical analyzer (TMA) for ambient curing UP and epoxy resins. Shrinkage readings obtained from the newly developed robust technique with the rheometer concur well with readings from the traditional pycnometric method. They also coincide within the accepted literature values of 7–10% and 3.5–4.5% for the UP and epoxy systems, respectively. Shrinkage measurements during post-cure were effectively carried out at an elevated temperature, suggesting that the methodology provided can be applied to non-ambient curing systems. The TMA was found to be unsuccessful in measuring shrinkage reliably.

Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

Technologies for automated fibre lay-up have proven their usefulness in composites manufacturing. Further development of the technologies, such as Automated Dry Fibre Placement (ADFP), allow further reduction of waste and increase of the design space through tow steering which enables creation of composites with tailored properties. Tow steering is, however, limited by possible defects such as wrinkles which result from mismatch of fibre length and steering path. This paper addresses wrinkle formation at different steering radii and provides a closed-form solution for the problem. Experimental results are used for estimation of the model parameters and validation of the model. An analytical framework is used to explore effects of processing parameters on defect formation. It was found that the tack stiffness has the greatest influence on defect formation. Parametric studies showed that increase of the temperature within the admissible temperature window can improve the tack properties and hence improve the lay-up.

Finite element simulation with cohesive contact is presented, to correlate the vacuum assisted RTM process and the bending performance of Omega beams. The model considers the process induced variations, including part thickness, resin rich pockets and voids. The bending performance prediction relies on cohesive contact to model delamination initiation and propagation. Computing efficiency is achieved by mesh scaling. The modelling approach applies to three variations of Omega beams with the different mode-mixture ratios. The finite element predictions result in a high degree of agreement with the experimental measurements.

A recently developed peel test designed to simulate the automated tape lay-up (ATL) process was used to measure tack and dynamic stiffness of newly developed ATL prepregs. Resin was extracted from the prepreg process before impregnation of the fibres. Isothermal small amplitude frequency sweeps were carried out in shear rheology to determine time–temperature superposition parameters in the form of Williams–Landel–Ferry equation. Gel permeation chromatography and differential scanning calorimetry demonstrated that the resin was not significantly changed during the prepregging process. The WLF parameters were used to transpose isothermal tack and dynamic stiffness results with excellent agreement found. This relationship offers manufacturers using composite prepreg a method to maximise and maintain tack levels at different feed rates by appropriate changes in temperature. This is of significant importance in improving the reliability of automated composite lay-up processes such as AFP and ATL, whose feed rate must vary to accommodate lay-up operations.

Resin chemical shrinkage dictates the surface integrity and the roughness of a composite structure. Thus, to minimize surface failures and to produce a good surface quality it is a requisite to be able to measure and track resin shrinkage during the cure process. This manuscript investigates and evaluates the measuring and monitoring of real-time resin shrinkage using a rheometer, a helium-based pycnometer and a thermo-mechanical analyzer (TMA) for ambient curing UP and epoxy resins. Shrinkage readings obtained from the newly developed robust technique with the rheometer concur well with readings from the traditional pycnometric method. They also coincide within the accepted literature values of 7–10% and 3.5–4.5% for the UP and epoxy systems, respectively. Shrinkage measurements during post-cure were effectively carried out at an elevated temperature, suggesting that the methodology provided can be applied to non-ambient curing systems. The TMA was found to be unsuccessful in measuring shrinkage reliably.

Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

Technologies for automated fibre lay-up have proven their usefulness in composites manufacturing. Further development of the technologies, such as Automated Dry Fibre Placement (ADFP), allow further reduction of waste and increase of the design space through tow steering which enables creation of composites with tailored properties. Tow steering is, however, limited by possible defects such as wrinkles which result from mismatch of fibre length and steering path. This paper addresses wrinkle formation at different steering radii and provides a closed-form solution for the problem. Experimental results are used for estimation of the model parameters and validation of the model. An analytical framework is used to explore effects of processing parameters on defect formation. It was found that the tack stiffness has the greatest influence on defect formation. Parametric studies showed that increase of the temperature within the admissible temperature window can improve the tack properties and hence improve the lay-up.

Finite element simulation with cohesive contact is presented, to correlate the vacuum assisted RTM process and the bending performance of Omega beams. The model considers the process induced variations, including part thickness, resin rich pockets and voids. The bending performance prediction relies on cohesive contact to model delamination initiation and propagation. Computing efficiency is achieved by mesh scaling. The modelling approach applies to three variations of Omega beams with the different mode-mixture ratios. The finite element predictions result in a high degree of agreement with the experimental measurements.

Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry whereas in reality it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

A recently developed peel test designed to simulate the automated tape lay-up (ATL) process was used to measure tack and dynamic stiffness of newly developed ATL prepregs. Resin was extracted from the prepreg process before impregnation of the fibres. Isothermal small amplitude frequency sweeps were carried out in shear rheology to determine time–temperature superposition parameters in the form of Williams–Landel–Ferry equation. Gel permeation chromatography and differential scanning calorimetry demonstrated that the resin was not significantly changed during the prepregging process. The WLF parameters were used to transpose isothermal tack and dynamic stiffness results with excellent agreement found. This relationship offers manufacturers using composite prepreg a method to maximise and maintain tack levels at different feed rates by appropriate changes in temperature. This is of significant importance in improving the reliability of automated composite lay-up processes such as AFP and ATL, whose feed rate must vary to accommodate lay-up operations.

Resin chemical shrinkage dictates the surface integrity and the roughness of a composite structure. Thus, to minimize surface failures and to produce a good surface quality it is a requisite to be able to measure and track resin shrinkage during the cure process. This manuscript investigates and evaluates the measuring and monitoring of real-time resin shrinkage using a rheometer, a helium-based pycnometer and a thermo-mechanical analyzer (TMA) for ambient curing UP and epoxy resins. Shrinkage readings obtained from the newly developed robust technique with the rheometer concur well with readings from the traditional pycnometric method. They also coincide within the accepted literature values of 7–10% and 3.5–4.5% for the UP and epoxy systems, respectively. Shrinkage measurements during post-cure were effectively carried out at an elevated temperature, suggesting that the methodology provided can be applied to non-ambient curing systems. The TMA was found to be unsuccessful in measuring shrinkage reliably.

Technologies for automated fibre lay-up have proven their usefulness in composites manufacturing. Further development of the technologies, such as Automated Dry Fibre Placement (ADFP), allow further reduction of waste and increase of the design space through tow steering which enables creation of composites with tailored properties. Tow steering is, however, limited by possible defects such as wrinkles which result from mismatch of fibre length and steering path. This paper addresses wrinkle formation at different steering radii and provides a closed-form solution for the problem. Experimental results are used for estimation of the model parameters and validation of the model. An analytical framework is used to explore effects of processing parameters on defect formation. It was found that the tack stiffness has the greatest influence on defect formation. Parametric studies showed that increase of the temperature within the admissible temperature window can improve the tack properties and hence improve the lay-up.

Finite element simulation with cohesive contact is presented, to correlate the vacuum assisted RTM process and the bending performance of Omega beams. The model considers the process induced variations, including part thickness, resin rich pockets and voids. The bending performance prediction relies on cohesive contact to model delamination initiation and propagation. Computing efficiency is achieved by mesh scaling. The modelling approach applies to three variations of Omega beams with the different mode-mixture ratios. The finite element predictions result in a high degree of agreement with the experimental measurements.

A recently developed peel test designed to simulate the automated tape lay-up (ATL) process was used to measure tack and dynamic stiffness of newly developed ATL prepregs. Resin was extracted from the prepreg process before impregnation of the fibres. Isothermal small amplitude frequency sweeps were carried out in shear rheology to determine time–temperature superposition parameters in the form of Williams–Landel–Ferry equation. Gel permeation chromatography and differential scanning calorimetry demonstrated that the resin was not significantly changed during the prepregging process. The WLF parameters were used to transpose isothermal tack and dynamic stiffness results with excellent agreement found. This relationship offers manufacturers using composite prepreg a method to maximise and maintain tack levels at different feed rates by appropriate changes in temperature. This is of significant importance in improving the reliability of automated composite lay-up processes such as AFP and ATL, whose feed rate must vary to accommodate lay-up operations.

Resin chemical shrinkage dictates the surface integrity and the roughness of a composite structure. Thus, to minimize surface failures and to produce a good surface quality it is a requisite to be able to measure and track resin shrinkage during the cure process. This manuscript investigates and evaluates the measuring and monitoring of real-time resin shrinkage using a rheometer, a helium-based pycnometer and a thermo-mechanical analyzer (TMA) for ambient curing UP and epoxy resins. Shrinkage readings obtained from the newly developed robust technique with the rheometer concur well with readings from the traditional pycnometric method. They also coincide within the accepted literature values of 7–10% and 3.5–4.5% for the UP and epoxy systems, respectively. Shrinkage measurements during post-cure were effectively carried out at an elevated temperature, suggesting that the methodology provided can be applied to non-ambient curing systems. The TMA was found to be unsuccessful in measuring shrinkage reliably.