Fast-curing epoxy resins enable substantial reduction of cycle times during production of thermoset polymer matrix composites. Due to the snap-cure behaviour, both characterisation and processing of these resins are associated with high complexity which motivates the development of a high-fidelity framework for the prediction of the process-dependent behaviour ranging from experiment to model validation. In order to determine influence of time, temperature, and degree of cure, a multitude of rheometer and dynamic mechanical analysis experiments are conducted and evaluated. Building on the experimental results, a material model based on a generalised Maxwell model is developed. It is calibrated on the results obtained in the tests and shown to describe the material’s behaviour with high accuracy under all investigated conditions. The model’s predictive capabilities are further tested by applying it to a dynamic mechanical analysis, exposing the model to previously unknown loading and temperature conditions. It is demonstrated that the model is capable of predicting such changing boundary conditions with high accuracy.

Process-induced surface waviness effects represent a major concern for series production of high-quality lightweight structures based on fiber reinforced plastics (FRP). This paper suggests a method for the numerical prediction of these effects by using the example of processing glass fiber reinforced plastics (GFRP) in a resin transfer molding (RTM) process. The influence of reaction kinetics, chemical shrinkage and cure-dependent viscoelastic properties of the resin are taken into account. Furthermore, the dependence of surface quality on curing cycle, consolidation pressure, textile architecture and thickness of neat resin layer (NRL) at the part surface are investigated. The work is based on published material data and a visco-thermo-elastic simulation approach which has been previously presented and validated. All numerical results are compared to the surfaces of FRP plates that were manufactured with the corresponding parameter variations. Based on a literature survey, different surface waviness values have been identified for comparison of experimental and numerical results. Satisfactory agreement between experiments and simulations is found. Furthermore, it is shown that the analyzed NRL thickness has no relevant influence on the surface waviness while the curing temperature significantly affects the surface waviness. The role of relaxation-induced change of the surface waviness is highlighted by performing long-term measurements and corresponding time-dependent simulations. It is concluded that relaxation plays a decisive role in the appropriate selection of the subsequent surface finishing process. The suggested simulation approach provides a basis for optimization strategies to improve surface quality and reduce post-processing effort.

For fiber‐reinforced plastics, the strain‐rate dependent response is governed by the matrix behavior. In this work, the Goldberg model is considered for the epoxy matrix constitutive material model. Moreover, the strain‐rate dependency is achieved by direct influence on the elastic modulus, the inelastic strain, and the material strain to failure. In addition, an anisotropic damage response is implemented and extended through a strain‐rate dependent definition. Since the constitutive model relies on nonphysical parameters, a parameter study is further performed. Additional numerical investigations using a micro‐mechanical model are performed. Tension and shear loading conditions are evaluated and the influence of different strain rates is explored. Furthermore, the implemented anisotropic damage model is compared and discussed against an isotropic damage model.