Thermal optimization of composite autoclave molds using the shift factor approach for boundary condition estimation

Abstract

Thermal optimization of autoclave molds is essential to increase part quality, reduce manufacturing costs and increase autoclave capacity. Previous experience-based tooling designs allowed an optimization only after the mold was manufactured and tested. Manufacturing process simulation provides the capability for virtual tooling optimization within the design phase. Thereby, the range of possible optimizations increases and the tooling cost decreases. In order to use manufacturing process simulation efficiently, fast but accurate simulation methods must be available. The so-called shift factor approach was previously presented by the authors. This paper takes up the given approach and explains different influences on mold heat-up and how they can be covered in a thermal tooling simulation on an industrial scale. Proof of the simulation accuracy under realistic manufacturing conditions is provided together with an example of its application.