Finite-element Investigation into Curing-induced Deformations of Carbon/Epoxy Composite Large-opening Support Structures

LIANG Chunzu; LUO Jintao; LIU Qiang; SUN Tianfeng; SONG Zidie

doi:10.3969/j.issn.1674-6457.2025.09.021

PDF(8045 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 212-221. DOI: 10.3969/j.issn.1674-6457.2025.09.021

Composites Forming

Finite-element Investigation into Curing-induced Deformations of Carbon/Epoxy Composite Large-opening Support Structures

LIANG Chunzu¹, LUO Jintao¹, LIU Qiang¹, SUN Tianfeng^1,*, SONG Zidie^1,2

Author information +

History +

Abstract

The work aims to establish a predictive model for the overall deformation of a large-opening support structure made of high-modulus carbon fiber reinforced polymer (CFRP) composites, incorporating the effects of the inherent curing shrinkage and thermal deformation of the composite and the structural design of the large opening. Firstly, the performance of the high-modulus carbon fiber composite system was characterized. Subsequently, the viscoelastic constitutive model was employed to explore the impact of the opening sequence process before and after curing on the overall structural deformation of the support structure through the finite element method. Compared to the process of first curing and then opening, the process of first opening and then cutting resulted in less curing deformation, reducing it by approximately 0.56 mm. However, the residual stress of the former was greater, with a difference of over 20 MPa between the two processes. This was because the process of first curing and then opening released residual stresses, which led to greater deformation. A viscoelastic constitutive model that captures the coupled effects of curing degree and temperature on the mechanical properties of composites is established, which accurately predicts deformation and warpage in composite laminates. Based on these predictions, a deformation-control strategy is implemented to ultimately define an optimized curing process for the carbon fiber/epoxy composites.

Key words

composites / curing deformation / support structure / opening process / finite element analysis

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

LIANG Chunzu, LUO Jintao, LIU Qiang, SUN Tianfeng, SONG Zidie. Finite-element Investigation into Curing-induced Deformations of Carbon/Epoxy Composite Large-opening Support Structures[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 212-221 https://doi.org/10.3969/j.issn.1674-6457.2025.09.021

References

[1] 李威, 郭权锋. 碳纤维复合材料在航天领域的应用[J]. 中国光学, 2011, 4(3): 201-212.
LI W, GUO Q F.Application of Carbon Fiber Composites to Cosmonautic Fields[J]. Chinese Journal of Optics, 2011, 4(3): 201-212.
[2] 马立敏, 张嘉振, 岳广全, 等. 复合材料在新一代大型民用飞机中的应用[J]. 复合材料学报, 2015, 32(2): 317-322.
MA L M, ZHANG J Z, YUE G Q, et al.Application of Composites in New Generation of Large Civil Aircraft[J]. Acta Materiae Compositae Sinica, 2015, 32(2): 317-322.
[3] LI Z L, DENG L B, KINLOCH I A, et al.Raman Spectroscopy of Carbon Materials and Their Composites: Graphene, Nanotubes and Fibres[J]. Progress in Materials Science, 2023, 135: 101089.
[4] ZHANG Y H, LING Y Q, ZHANG H, et al.In Situ Construction of Silicon-Containing Carbon Layer by Hyper Silicone-Branched Structure Endows Epoxy/Carbon Fiber Composites with High Strength and Ablation Resistance[J]. Reactive and Functional Polymers, 2024, 203: 106004.
[5] AOUD B E, ALTHOBAITI S, ALJOHANI A F, et al.Micromechanical Modeling of Thermal Conductivities of Unidirectional Carbon Fiber/Epoxy Composites Containing Carbon Nanotube/Graphene Hybrids[J]. International Communications in Heat and Mass Transfer, 2024, 157: 107726.
[6] 杨博, 权银洙, 王菲, 等. 大尺寸复合材料Z形加强筋制造技术[J]. 复合材料科学与工程, 2023(10): 47-51.
YANG B, QUAN Y Z, WANG F, et al.Manufacturing Technology of Z-Shaped Stiffener for Large Scale Composites[J]. Composites Science and Engineering, 2023(10): 47-51.
[7] 元振毅, 魏方见, 孔令飞, 等. 模具-复合材料相互作用的复合材料固化变形仿真方法研究[J]. 复合材料科学与工程, 2023(10): 10-16.
YUAN Z Y, WEI F J, KONG L F, et al.Simulation Method for Curing Deformation of Composite Part Considering Tool-Part Interaction[J]. Composites Science and Engineering, 2023(10): 10-16.
[8] GU S H, WANG C C, ZHANG W F, et al.Simultaneous Modification and Solidification of Bamboo Fiber/Epoxy Composites[J]. Composite Structures, 2024, 340: 118204.
[9] GUPTA N, NGUYEN N Q, ROHATGI P K.Analysis of Active Cooling through Nickel Coated Carbon Fibers in the Solidification Processing of Aluminum Matrix Composites[J]. Composites Part B: Engineering, 2011, 42(4): 916-925.
[10] 陈文, 赵月青, 韩舒, 等. 复合材料U形混杂夹层结构固化变形及控制研究[J]. 高科技纤维与应用, 2023, 48(1): 54-60.
CHEN W, ZHAO Y Q, HAN S, et al.Study on Curing Deformation Control of U-Shaped Hybrid Sandwich Composite Structure[J]. Hi-Tech Fiber and Application, 2023, 48(1): 54-60.
[11] KRAVCHENKO O G, KRAVCHENKO S G, PIPES R B.Cure History Dependence of Residual Deformation in a Thermosetting Laminate[J]. Composites Part A: Applied Science and Manufacturing, 2017, 99: 186-197.
[12] BOGETTI T A, GILLESPIE J W.Process-Induced Stress and Deformation in Thick-Section Thermoset Composite Laminates[J]. Journal of Composite Materials, 1992, 26(5): 626-660.
[13] 翁琳, 吴爱中, 张镇国, 等. 颗粒团聚分布的复合材料数值模型[J]. 精密成形工程, 2024, 16(4): 79-86.
WENG L, WU A Z, ZHANG Z G, et al.Numerical Model of Composite Materials with Agglomerated Particles[J]. Journal of Netshape Forming Engineering, 2024, 16(4): 79-86.
[14] JOHNSTON A, VAZIRI R, POURSARTIP A.A Plane Strain Model for Process-Induced Deformation of Laminated Composite Structures[J]. Journal of Composite Materials, 2001, 35(16): 1435-1469.
[15] 孙亮亮, 丁安心, 祖磊, 等. 三维粘弹性复合材料层合板固化残余应力研究[J]. 应用力学学报, 2016, 33(5): 779-785.
SUN L L, DING A X, ZU L, et al.Research on Process-Induced Residual Stress for Composite Laminates Based on Three-Dimensional Viscoelasticity[J]. Chinese Journal of Applied Mechanics, 2016, 33(5): 779-785.
[16] 戴棣, 乔新. 粘弹性基体复合材料层合板的固化残余应力和曲率变化[J]. 复合材料学报, 2000, 17(3): 38-41.
DAI D, QIAO X.Variation of Cure Residual Stress and Curvature of Resin Matrix Composite Laminates[J]. Acta Materiae Compositae Sinica, 2000, 17(3): 38-41.
[17] TWIGG G, POURSARTIP A, FERNLUND G.An Experimental Method for Quantifying Tool-Part Shear Interaction during Composites Processing[J]. Composites Science and Technology, 2003, 63(13): 1985-2002.
[18] 马云荣, 贺继林, 李栋, 等. 树脂基复合材料曲面结构件固化变形数值模拟[J]. 复合材料学报, 2015, 32(3): 874-880.
MA Y R, HE J L, LI D, et al.Numerical Simulation of Curing Deformation of Resin Matrix Composite Curved Structure[J]. Acta Materiae Compositae Sinica, 2015, 32(3): 874-880.
[19] 张纪奎, 郦正能, 关志东, 等. 热固性复合材料固化过程三维有限元模拟和变形预测[J]. 复合材料学报, 2009, 26(1): 174-178.
ZHANG J K, LI Z N, GUAN Z D, et al.Three-Dimensional Finite Element Simulation and Prediction for Process-Induced Deformation of Thermoset Composites[J]. Acta Materiae Compositae Sinica, 2009, 26(1): 174-178.
[20] 申智春, 梁鲁, 郑钢铁, 等. 某型卫星有效载荷支架振动抑制[J]. 宇航学报, 2006, 27(3): 503-506.
SHEN Z C, LIANG L, ZHENG G T, et al.Vibration Suppression of a Payload Bracket in a Satellite[J]. Journal of Astronautics, 2006, 27(3): 503-506.
[21] 李林, 王栋, 谭陆洋, 等. 微小卫星星敏感器支架的优化设计与试验[J]. 光学精密工程, 2016, 24(6): 1352-1358.
LI L, WANG D, TAN L Y, et al.Optimization Design and Test for Bracket of Star Sensor in Micro-Satellite[J]. Optics and Precision Engineering, 2016, 24(6): 1352-1358.
[22] 刘学术, 乔仁勇. 基于加工变形的复合材料固化残余应力评估方法[J]. 复合材料学报, 2023, 40(7): 4260-4269.
LIU X S, QIAO R Y.Cure-Induced Residual Stresses Assessment of Composite Materials Based on Machining Deformation[J]. Acta Materiae Compositae Sinica, 2023, 40(7): 4260-4269.
[23] 钱鑫, 王雪飞, 马洪波, 等. 国内外PAN基高模量碳纤维的技术现状与研究进展[J]. 合成纤维工业, 2021, 44(5): 58-64.
QIAN X, WANG X F, MA H B, et al.Technology Status and Research Progress of PAN-Based High-Modulus Carbon Fibers in China and Abroad[J]. China Synthetic Fiber Industry, 2021, 44(5): 58-64.
[24] 周秀燕, 王梓桥, 匡乃航, 等. 国产高模碳纤维增强复合材料性能研究[J]. 纤维复合材料, 2022, 39(2): 53-56.
ZHOU X Y, WANG Z Q, KUANG N H, et al.Study on Properties of Domestic High Modulus Carbon Fiber Reinforced Composites[J]. Fiber Composites, 2022, 39(2): 53-56.
[25] MAO W J, LI S Q, WANG X Q, et al.Characterization and Estimation of Specific Heat Capacity for Composite Phase Change Material[J]. Thermal Science and Engineering Progress, 2024, 55: 103011.
[26] LORENZ N, DYER W E, KUMRU B.Exploring the Cure State Dependence of Relaxation and the Vitrimer Transition Phenomena of a Disulfide-Based Epoxy Vitrimer[J]. Journal of Polymer Science, 2025, 0: 20250463.
[27] BOGETTI T A, GILLESPIE J.Two-Dimensional Cure Simulation of Thick Thermosetting Composites[J]. Journal of Composite Materials, 1991, 25(3): 239-273.
[28] LONG Y F, YU W B, PIPES R B, et al.Simulation of Composites Curing Using Mechanics of Structure Genome Based Shell Model[J]. Composites Part A: Applied Science and Manufacturing, 2022, 154: 106766.
[29] KANG C, ZHAN J, LIU Z, et al.Numerical Study of the Axial Compression Strength for Nano-Reinforced Filament-Wound Riser Considering Curing Residual Stress[J]. Applied Ocean Research, 2024, 142: 103829.
[30] KIM Y K, WHITE S R.Process-Induced Stress Relaxation Analysis of AS4/3501-6 Laminate[J]. Journal of Reinforced Plastics and Composites, 1997, 16(1): 2-16.
[31] SOUDAGAR M E M, UMARFAROOQ M A, GOUDA P S, et al. Implications of End Cooling Rates on the Mechanical, Viscoelastic, and Interlaminar Fracture Properties of the Unidirectional Glass Fiber/Epoxy Composites[J]. Composites Part A: Applied Science and Manufacturing, 2025, 190: 108631.
[32] UM H J, JU Y M, LEE D W, et al.Reduced Warpage in Semiconductor Packages: Optimizing Post-Cure Temperature Profile Considering Cure Shrinkage and Viscoelasticity of Epoxy Molding Compound[J]. Materials & Design, 2024, 245: 113265.
[33] LI Z Y, LIU S T, XU W W, et al.Exploring the Impact of Rib Configuration on Cure-Induced Distortion and Residual Stress in Co-Cured Composite Stiffened Panels[J]. Thin-Walled Structures, 2025, 216: 113740.
[34] XIAO Y, LI D S, QIAN Z, et al.An Experimental and Numerical Study of Curing Deformation Considering Tool-Part Interaction for Two-Step Curing Tooling Composite Materials[J]. Journal of Manufacturing Processes, 2023, 94: 435-453.
[35] ZHI J, YANG B, LI Y, et al.Multiscale Thermo-Mechanical Analysis of Cure-Induced Deformation in Composite Laminates Using Direct FE²[J]. Composites Part A: Applied Science and Manufacturing, 2023, 173: 107704.