Multiscale Multiphysics Process Modelling for the Manufacture of Aerospace Composites

Overview: This exciting PhD research project will develop state of the art Multiscale Multiphysics methods to model the consolidation and curing processes during the manufacture of large-scale composite aerospace structures.

The PhD student will collaborate closely with:
- Composite Research Unit
- Numerical Analysis Group
- GKN Aerospace.

Background: Whilst the basic advantages of composite materials are well proven, they are often compromised by high costs, long development time, and poor quality due to manufacturing defects. This is particularly the case for the complex structures found in aerospace applications. Laminates are made by layering a series of thin carbon fibre plies on to a tool; pressure and heat are then applied to ensure the laminate conforms to the tool surface, resin is evenly dispersed throughout and the part cures. This manufacturing method involves many different physical processes on all scales. Making large-scale components adds even more complexity, and parts are particularly vulnerable to developing a variety of defects, for example wrinkling. Depending on the defects’ severity, the structural integrity of the part might be compromised, leading to expensive wholesale rejection. The Composite Research Unit has developed a higher-order multiscale continuum model for an elastic layered material, which includes the interlayer mechanics without explicitly defining the layer geometry. This method has shown the potential to capture small-scale defects at a fraction of the computational expense when compared to conventional finite element methods. For real impact in the aerospace sector this method must be extended to include more realistic micro-mechanical-multiphysics behaviour that incorporates resin flow, temperature distribution and cure kinetics

Key Objectives: (1) Develop a detailed understanding of the micromechanics of uncured carbon fibre composites, through fine scale computations and experiments. (2) Extend existing multiscale capabilities to capture complex microscale processes (3) Implement macro-scale process simulations to real aerospace structures.


Essential: Applicants should have or expect to achieve at least an upper second-class Honours degree, or equivalent qualifications, in a relevant engineering or applied mathematics discipline.
Desirable: Interest/Experience in:
- Mathematical Modelling (Elasticity / Flow)
- Numerical Methods for PDEs (e.g. Finite Element Method)
- Composite Materials / Structures in particularly with respect to Aerospace Applications.
All applications should be submitted on-line http://www.bath.ac.uk/study/pg/apply