FE modeling and numerical implemtation of flow-deformation processes in composites manufacturing

Paper in proceeding, 2013

In present work, we attempt to unify the modeling of different sub-processes under the umbrella of two-phase porous media theory. Two sub processes are considered: (1) the wetting and compaction of individual plies and (2) the overall preform deformation and macroscopic Darcian flow. The idea is to identify a set of relevant constituents, i.e. particles, voids and liquids, and assign them to pertinent media. The result is a set of overlapping continuous media, each having its own density-, velocity- and stress field on the macroscopic scale. In addition, we introduce internal variables to describe irreversible micro-processes in the system, such as microscopic infiltration and preform deformation. In this work we extend the previous developments, coupling the preform deformation on different scales to the process of micro infiltration, with respect to the modeling of the micro-compaction as well as the Darcian interaction on the macro scale. A coupled displacement-pressure, geometrically non-linear, finite element model is presented. The approach is applied to a representative numerical example where we used parameter values out of the literature and estimates from our own micrographs.