Curing simulation and experimental analysis of composite segmented tools for aerospace applications

Abstract The composite segmented tools, used as the internal mandrel, are crucial in the integrated curing process of aerospace composite tanks. Their precise manufacturing demands stringent curing process requirements. Current studies lack reports on the curing simulation and process optimization of the segmented tools, making it challenging to provide effective guidance for the high‐quality manufacturing of aerospace composite tanks. This study focuses on the composite segmented tools for a Φ3.35 m liquid oxygen tank. The curing kinetics equations and thermophysical properties of T800/epoxy composites were tested and fitted. Finite element prediction models for the temperature and deformation evolution during the curing process were constructed. Based on the orthogonal experimental design, the curing parameters were optimized, and an engineering trial of the composite panel was completed. The results indicate that the heating rate has the most significant impact on the curing deformation of segmented tools, while the curing temperature has the greatest effect on curing uniformity. Under the optimized process parameters, the curing deformation of the composite panel obtained by the finite element model only has a 6.67% error compared to the experimental results, which not only validates the accuracy of the simulation models but also achieves precise manufacturing of the composite segmented tools. Highlights Thermophysical properties of T800/epoxy composites were tested and fitted. FE models during the curing process of segmented tools were constructed. Curing parameters were optimized through orthogonal experimental design. Curing experiments of the panel verified the accuracy of the simulations.