Simulation pour l'aide a l'optimisation et fabrication intelligente des composites par injection sous renfort

The goal of this thesis is to develop modeling tools designed towards engineering needs of the composites manufacturing industry. Most of the discussion will be focused on the resin transfer moulding process (RTM) although most of it applies also to the liquid composite moulding processes in general.' In this thesis, the scientific notions are reviewed, explained and simplified to help engineers in deeply understanding the capability of composite modeling.;The second chapter gives an exhaustive review of the numerical filling algorithms dedicated to the RTM process. Each algorithm is explained and tested for its precision and performance. This section includes the proposition a new filling algorithm based on finite element and Monte-Carlo methods. This algorithm shows an average speedup of four times the speed of the equivalent implicit algorithm. It can use meshes that are poorly adapted to filling simulation as those created for structural analysis.;The third chapter present the details of a new software algorithm. This software was created to vulgarise the use of numerical simulations. A methodology is proposed using analytical, semi-analytical and numerical solution to delimit the functional space of a specific process and to compare different processing scenarios in real time. By combining physical constraints with numerical results, the software is able to plot the moldability diagram. This diagram can be plotted on different forms exposing visually different optimal solution of a given problem. One novelty of the software is to include the intelligence and experience of the user in the optimisation loop. Also, it should be noted that this software possesses a 3D game interface that enable to use it as would children do without reading the instruction manual.;Engineers often ask about the applicability of scientific models in an industrial environment. The fourth chapter described the design of a new measurement apparatus half way between numerical modeling and physical manufacturing of real part. It is a heated small scale mold instrumented with heat flux sensor and thermocouples. This mini-mould was conceived to be used as an industrial differential scanning calorimeter. This chapter reviews the work done during this thesis from the first prototype to the actual version describing the computer, electronic and mechanical design. Software was developed for this tool that enable network users to control the experiments. This will allows engineers to reach specialists from over the world to get their feedback in real time.;The first chapter starts by defining the vocabulary needed to understand the RTM process. The physical models found in literature are introduced one at a time. When possible some analytical solutions and graphics are proposed to give a first understanding of the phenomenon. Then, scientific characterisation tools for quantifying the physical parameters applied to models are presented followed by a description of the sensing devices available for the molds. This chapter finishes by introducing the optimization techniques that are widely used in the literature.;Finally, the last chapter gives a short discussion of the overall work and propose some future works. Some annexes were also appended to this thesis.;To conclude, this document proposed a series of scientific modeling tools addressed toward industrial needs. From finite elements and analytical model up to small scale simulator, this thesis has given different levels of modeling. The author hopes that it will put forward the use of modeling in composite manufacturing less prone to trials and errors and more toward intelligence and knowledge.