Thermal response of frame-like composite structures to analytically assess manufacturing distortion

The proposed approach assesses frame-like composite parts prone to distortion without needing a full-scale finite element simulation. These structures are reduced to a series of constant cross-sections and curvatures. A simplified shape response of each thin-walled composite cross-section during curing is analytically obtained by employing homogenization methods at different geometrical levels. This includes a novel approximation method for the mechanical properties of a T-section including a gusset filler. The model is validated against a currently deployed finite element approach. A good agreement is reached for the thermal response of a gusset and a cross-section, whereas for an extruded frame-like structure, the analytically calculated deformation is about 20% higher than the simulated one. The cause is identified and solutions are proposed. Nevertheless, knowing its limitation, the ease of use together with the high potential for automation makes this altogether a possible method for predicting process-induced deformation in the early design phase.