Investigating and Predicting Preforming Effects on Resin Solidification of Woven Carbon Fiber Reinforced Plastics (CFRPs) Using Multiscale Modeling and Experiments (ECS 24208912)
The goal of this project is to experimentally investigate and numerically predict preforming effects on resin solidification of woven carbon fiber reinforced plastics (CFRPs). To achieve this goal, we will establish (1) a novel multiscale modeling approach for resin solidification of preformed CFRPs, and (2) an innovative modeling method of CFRP performance integrated with thermoforming effects, such that both the solidification process and its end-product performance can be analyzed coherently.
Initial blank geometry design for thermoforming of carbon fiber reinforced plastics (CFRPs) based on finite element analysis (FEA) (Direct Grant for Research 4055130)
Te goal of this project is to develop a FEA-modeling-based design method to optimize the initial blank geometry for CFRP thermoforming. The specific tasks to achieve the goal of this project include: (1) Build up and implement advanced surface interaction model to simulate the most popular multiple layer thermoforming; (2) Design and perform physical thermoforming experiments to validate the proposed design method; and (3) Automate the design-manufacturing procedure by integrating the modeling-based design method with trimming robots to precisely produce optimal CFRP blanks for thermoforming.
Optimization for preforming of carbon fiber reinforced plastic (CFRP) parts based on numerical modeling (ITS/134/20)
The research objective of this project is to develop a cutting-edge numerical modeling-based optimization method for carbon fiber reinforced plastic (CFRP) preforming to minimize material consumption, process cost, and development period while maximize part performance. To achieve this goal, the proposed method will be established through two milestones: Milestone 1 – pure numerical optimization and Milestone 2 – physical prototyping. For Milestone 1, the PI will lead the research team to develop (a) an optimization algorithm, (b) a prepreg interaction model, (c) a design approach for stacking configuration, and (d) a design approach for temperature and preforming forces design. For Milestone 2, programs and prototypes that can (a) generate trimming lines and (b) identify orientations for prepregs and parts from numerical models will be built in order to bridge virtual optimization to real world production.
Modeling of environmental effects on performance degradation of offshore wind turbine blades made by carbon fiber reinforced plastics (CFRPs) (SHIAE RNE-p2-20)
This project aims to develop a cutting-edge MD (molecular dynamics)-FEA integrated modeling method to simulate performance degradation of CFRP wind turbine blades with offshore environmental effects included. Upon completion, a numerical tool will be established to aid material selection and new material design for CFRPs that are to be applied under marine or other harsh conditions. The underlying principles about electrochemistry erosion at CFRP-metal interfaces can also be obtained to guide construction of CFRP part joints and selection of component materials for water-involved applications.
Manufacturing, Testing and Mechanical Modeling of Composite Structural Batteries with 3D Geometry
The goal of the proposed work is to establish manufacturing and analyzing methods for carbon fiber reinforced plastic (CFRP) structural batteries with 3D geometry to enable utilization of structural batteries in zero-emission electric vehicles (EVs) for enhanced performance, boosting EV development, reducing greenhouse gas emissions and increasing sustainability of global ecosystem. To achieve this goal, we will fabricate and study deformed carbon fabrics coated with electrode materials, produce and test 3D structural batteries made with carbon fabric electrodes and quasi-solid polymer electrolyte, and establish a numerical modeling method to predict mechanical performance of the structural batteries considering manufacturing effects.
Multiscale modeling for out-of-plane behaviors of carbon fiber reinforced polymers (CFRPs) during thermoforming (GRF 14205923)
This project aims to numerically predict out-of-plane behaviors of woven carbon fiber reinforced plastics (CFRPs) during thermoforming. To achieve this goal, a multiscale approach will be established to model (1) resin squeeze-out and flow within preformed prepregs during compaction and (2) shrinkage of yarns and variation of thickness and fabric surface morphology of CFRPs caused by curing, such that process parameters and mold geometry can be designed virtually with high efficiency.