Cure cycle design for thermosetting-matrix composites fabrication under uncertainty

Design of the optimal cure temperature cycle is imperative for low-cost of manufacturing thermosetting-matrix composites. Uncertainties exist in several material and process parameters, which lead to variability in the process performance and product quality. This paper addresses the problem of determining the optimal cure temperature cycles under uncertainty. A stochastic model is developed, in which the parameter uncertainties are represented as probability density functions, and deterministic numerical process simulations based on the governing process physics are used to determine the distributions quantifying the output parameter variable. A combined Nelder–Mead Simplex method and the simulated annealing algorithm is used in conjunction with the stochastic model to obtain time-optimal cure cycles, subject to constraints on parameters influencing the product quality. Results are presented to illustrate the effects of a degree of parameter uncertainty, constraint values, and material kinetics on the optimal cycles. The studies are used to identify a critical degree of uncertainty in practice above which a rigorous analysis and design under uncertainty is warranted; below this critical value, a deterministic optimal cure cycle may be used with reasonable confidence.