A physics-based numerical model for prediction and compensation of the process-induced distortion of 3D woven composite (3DWC) is presented. A new tool-part interaction modelling method for the Resin Transfer Molding process is developed, in which the nonlinear material properties and non-thermoelastic distortion are taken into account. Flat and L-shaped 3DWC parts were fabricated and the process-induced distortions were evaluated. Adopting the input values determined by the warpages of flat parts, the spring-in of L-shaped parts predicted by the model is consistent with the experimental measurements. Based on the model, it is found that taking the warpage/spring-in of the uncompensated parts as the compensation value will result in a deviation between the manufactured parts and the nominal shape. An improved comprehensive compensation procedure is proposed and applied to an L-shaped 3DWC part. The result shows that the dimensional precision of the part can be significantly improved by the compensation process.

提出了一种基于物理的数值模型，用于预测和补偿3D编织复合材料（3DWC）的过程引起的变形。提出了一种考虑树脂材料的非线性和非热弹性变形的树脂传递模塑工艺的零件-零件相互作用建模方法。制作了扁平的和L形的3DWC零件，并对过程引起的变形进行了评估。采用由扁平零件的翘曲确定的输入值，由模型预测的L形零件的弹跳与实验测量结果一致。基于该模型，发现将未补偿零件的翘曲/弹入作为补偿值将导致制造零件与标称形状之间的偏差。提出了一种改进的综合补偿程序，并将其应用于L形3DWC零件。结果表明，通过补偿过程可以显着提高零件的尺寸精度。