Viscosity‐coupled curing simulation model for L‐shaped composites considering flow and compaction

Computational methods provide effective tools for the prediction of the curing behavior of composites, especially for large‐scale complex composite structures. The flow‐compaction analysis during curing receives insufficient attention in current studies. In this work, an integrated framework considering the heat transfer, the cross‐linking reaction, the flow and compaction, and the stress–strain module is established. A comprehensive resin flow termination criterion is proposed. L‐shaped composites with a stacking layer of [45/90/−45/0]s were fabricated, and the good agreement between the experimentally measured and the numerically predicted contour data validated the current model. Compared with Hubert's model, the prediction accuracy of the thickness and fiber volume content increases by 4.24% and 3.92%, respectively. Correlation analysis between the fiber volume ratio predicted by numerical methods and experimental results (94% for this method, −41% for Hubert's model) demonstrates the well‐capture of nonuniform fiber distribution in curved composites for the current strategy. The overall framework provides an accurate and promising tool for the prediction of the curing behavior of complex composite components. Highlights An integrated numerical methodology is proposed considering the resin flow and compaction. The viscosity‐temperature coupled feature of resin is considered in the permeability coefficients. A comprehensive resin flow termination criterion is proposed for an accurate prediction. The resin content, thickness, and spring‐in angle of L‐shaped laminates are characterized. The good correlation between the experimental and numerical results validates this method. Compared with the model proposed by Hubert, the prediction accuracy improves. An integrated curing simulation methodology considering resin flow and compaction.