Residual and build stresses arising in composite components during the manufacturing process can cause cracking of the matrix and significant distortions leading to difficulties in assembly and decrease of component performance. Several analytical models have appeared in the literature, which help to understand and estimate the magnitude of distortions, these however are limited to relatively simple geometries usually with single curvatures. Analysis of components with more complex geometries requires more sophisticated numerical tools. In this paper the LUSAS High Precision Moulding (HPM) integrated finite element environment for composite process simulation is introduced and validated against test components with single and double curvatures. The modelling technique introduced here is based on advanced non-linear material cure model combined with efficient composite elements. It provides the information about the buildup of residual stresses; part distortion and compensated tooling geometry that can be directly used by tooling manufacturers. Alternatively it is possible to analyse thin laminates assuming uniform cure across the laminate thickness where the analysis is conducted in three steps corresponding to cure shrinkage in the rubbery state, cool down from cure temperature and release from the tool. Obtained predictions are in excellent agreement with experimental and analytical data. The HPM product developed within LUSAS environment offers potential for eradication of costly and time-consuming trial and error methods that are currently taken in tool design for thermosetting composite parts.
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