Optimization of a Cohesive Zone Model to Predict Needle Insertion Forces in Carbon Fiber Preforms for Advanced Space Manufacturing

Institut

Lehrstuhl für Carbon Composites

Typ

Bachelorarbeit / Semesterarbeit / Masterarbeit /

Inhalt

theoretisch /  

Beschreibung

The performance of cryogenic liquid rocket engines can be significantly improved through the use of nozzle extensions that increase exhaust gas velocity and overall propulsion efficiency. Among the most promising advancements in this field are composite nozzle extensions (CNE) that offer a drastic reduction in engine mass, which is a critical factor in aerospace engineering (Valentine, P. G. & Gradl, P. R., 2019) (Fig. 1). CNEs are built based on a two-dimensional textile structure, strategically reinforced in the third dimension through advanced carbon fiber (CF) stitching. Cutting-edge textile manufacturing techniques, such as tufting (one-sided sewing), enable the cost-effective production of lightweight, high-performance components with complex geometries within the aerospace field (Fig. 2).

The reliability of the tufting process is often compromised by needle and thread breakage, primarily due to the use of thick material stacks as well as the brittleness of CF sewing threads in space-related manufacturing. To improve the reliability and scalability of the tufting process in this context, it is essential to predict the forces generated during the sewing of carbon fiber textile preforms. In this study, the needle insertion is simulated using a cohesive zone model. The objective of this work is to calibrate the parameters of the cohesive model based on experimental data obtained from needle insertion experiments. Specifically, the aim is to implement an optimization algorithm in order to fit the force-displacement curves, predicted by the finite element model in Abaqus, to those determined through the experiments.

Research focus of the thesis:

• Literature research and familiarization with the existing cohesive-based model of the tufting process
• Implementation of an optimization algorithm for the calibration of the cohesive model
• Discussion and documentation of the results

Voraussetzungen

Requirements:

• Structured and thorough work attitude
• Interest and knowledge about carbon-fiber reinforced plastics
• Experience with FEA software (Abaqus) and Python is beneficial
• Excellent knowledge of German or English language

Möglicher Beginn

sofort

Kontakt

Shima Norouzi, M.Sc.
Raum: 5504.01.407
Tel.: +49 89 289 15757
shima.norouzitum.de

Ausschreibung