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A TWO-PHASE ORTHOTROPIC MODEL FOR INTEGRATING RESIN FLOW AND STRESS DEVELOPMENT IN PROCESSING OF COMPOSITE MATERIALS

An extension of the Integrated Flow-Stress (IFS) model previously developed by the authors for a composite material system with isotropic constituents is presented here for the case where the reinforcing constituents possess general orthotropic properties. The IFS model couples the classical model for flow through porous media used typically to simulate the behaviour of the composite during the early stages of processing when the resin is liquid to the classical solid mechanics formulation that describes the behaviour of the cured composite when the resin behaves as a solid. These two formulations are integrated into a single formulation where the transitions of the governing equations between these two distinct regimes of behaviour occur in a smooth and seamless fashion. The orthotropic extension of the conservation equations and constitutive formulations in the IFS model are presented briefly. Adopting a u-v-P finite element formulation, the governing equations have been implemented in a MATLAB code and solved using an implicit solution method that considers both material and geometric nonlinearities. A case study is provided to show the capability of the developed computational framework for processing of composite materials and comparisons are made with the predicted results from the process simulation based on the stress model alone. The numerical case study demonstrates the significance of using the IFS model to capture the temporal and spatial variation of resin flow on the process outcome.