Dr Connie Qian, EPSRC Innovation Fellowship
Numerical Simulation of Combination of Carbon Fibre Prepreg and SMC
Compression moulding of fibre reinforced, fast-curing thermoset composites is an attractive solution for high-volume manufacturing of high performance, lightweight automotive parts.
While this process is commonly associated with either continuous, orientated fibre based prepreg or discontinuous fibre based Sheet Moulding Compound (SMC), combining both materials in a single process improves the manufacturability of high performance composite structures, and provides a new solution for integrating the functionalities of different materials.
Currently, there are no well-established process simulation models for compression moulding of either prepreg or SMC, mainly because the material behaviour under typical processing conditions is poorly characterised. Developing a process simulation model for prepreg and SMC hybrid is even more challenging as the interaction between the two materials need to be considered as well.
Dr Connie Qian's Fellowship aims to develop sophisticated process simulation models for compression moulding of prepreg and SMC, and ultimately deliver a model for the hybrid moulding process.
These will be achieved using a range of novel material characterisation methods developed as a part of this research, in order to understand the material behaviour of prepreg and SMC, and to provide material input data for process simulation. The models will be validated using a real-life demonstrator geometry to ensure they can be adopted as day-to-day process design tools.
Compression moulding of an SMC part: Experiment vs. simulation.
Impact on a broader range of communities.
Dr Qian's research addresses a grand challenge in the automotive composites sector by enhancing the robustness of existing processes via understanding of process science to deliver and accelerate growth.
It will also benefit a broader range of communities, for instance it will help the software developers to improve the capabilities of their products; it will guide the material manufacturer to tailor their products to suit the manufacturing process; and it will also encourage knowledge exchange with other catapult centres and other universities.