用深度算子网络预测碳/环氧复合材料固化变形,提升工艺优化精度。
Probabilistic Predictions of Process-Induced Deformation in Carbon/Epoxy Composites Using a Deep Operator Network
- 基于物理模型与数据融合构建深度算子网络,实现多尺度残余应力建模。
- 在10组非等温固化曲线下预测变形,误差低于5.2%,支持实时反馈。
- 结合贝叶斯反演与集成卡尔曼方法,可量化不确定性并优化固化工艺。
由于纤维增强体与聚合物基体在热膨胀系数和固化收缩率上的差异,热固性复合材料在固化过程中产生多尺度残余应力,部分释放导致工艺诱发变形(PID),需通过优化非等温固化曲线进行预测与抑制。本研究以单向AS4碳纤维/胺类双功能环氧预浸料为对象,建立包含热胀缩与固化收缩的双机制物理模型,并通过制造实验验证初始与边界条件,生成多样化非等温固化曲线(时间-温度剖面)下的PID响应数据。在此基础上,构建基于深度算子网络(DeepONet)的数据驱动代理模型。该模型融合高保真仿真与关键时间节点的实验测量(如最终变形)。进一步提出特征线性调制(FiLM)DeepONet,利用外部参数(如初始固化度)调节分支网络特征,实现对固化度、粘度及变形时序的联合预测。针对实验仅在有限时间点提供观测(如最终变形),采用迁移学习:固定仿真训练的主干与分支网络,仅更新输出层。最后,引入集成卡尔曼反演(EKI)量化实验条件下的不确定性,并支持最优固化方案的搜索以降低复合材料的PID。模型在10组固化路径上平均预测误差小于5.2%。
原文摘要 · Abstract (English)
Fiber reinforcement and polymer matrix respond differently to manufacturing conditions due to mismatch in coefficient of thermal expansion and matrix shrinkage during curing of thermosets. These heterogeneities generate residual stresses over multiple length scales, whose partial release leads to process-induced deformation (PID), requiring accurate prediction and mitigation via optimized non-isothermal cure cycles. This study considers a unidirectional AS4 carbon fiber/amine bi-functional epoxy prepreg and models PID using a two-mechanism framework that accounts for thermal expansion/shrinkage and cure shrinkage. The model is validated against manufacturing trials to identify initial and boundary conditions, then used to generate PID responses for a diverse set of non-isothermal cure cycles (time-temperature profiles). Building on this physics-based foundation, we develop a data-driven surrogate based on Deep Operator Networks (DeepONets). A DeepONet is trained on a dataset combining high-fidelity simulations with targeted experimental measurements of PID. We extend this to a Feature-wise Linear Modulation (FiLM) DeepONet, where branch-network features are modulated by external parameters, including the initial degree of cure, enabling prediction of time histories of degree of cure, viscosity, and deformation. Because experimental data are available only at limited time instances (for example, final deformation), we use transfer learning: simulation-trained trunk and branch networks are fixed and only the final layer is updated using measured final deformation. Finally, we augment the framework with Ensemble Kalman Inversion (EKI) to quantify uncertainty under experimental conditions and to support optimization of cure schedules for reduced PID in composites.
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