Experimental and Numerical Investigations on Minimization of Spring back Deformation in CFRP Parabolic Antenna Reflector Used for Space Applications

Abstract

The last few decades have witnessed a considerable increase in the use of carbon fiber reinforced polymer (CFRP) mainly for aerospace structures, automobiles, marine components, sporting goods and space applications. The selection of carbon fiber composite materials is based on the characterization and evaluation of thermo-mechanical properties. The characterization of epoxy-based composites is performed to obtain high-quality parts with greater consistency and to minimize the experimental work required to establish a cure cycle for new components. The use of prepregs for composites manufacturing offers the advantage of high fiber volume fractions and adaptability for manufacturing complex parts. Autoclave curing is widely practiced because of its robustness and has attracted the attention of industries and researchers. As autoclave curing is preferred for complicated parts requiring good dimension stability, warpage, spring-back deformation, and process induced deformations must be minimal. Understanding the cure behavior as well as resulted in thermo-mechanical properties of a thermosetting system are essential in the development and optimization of composites manufacturing processes. The development of residual stresses in the part and the mould is inevitable during the manufacturing of composite laminates as, the parts cure at high temperatures. The antenna reflector is a standalone device used for redirecting radio frequency energy or reflects electromagnetic waves in satellite communications. These high precision parabolic shape antenna reflectors used in the space communication satellites are made from CFRP material using an autoclave manufacturing process with backup structure. High dimensional fidelity is the primary challenge for the large size CFRP antenna reflectors used in space applications. The dimensional control of CFRP components mainly governed by the section of crucial process parameters. newlineIt is very much essential that the profile of the CFRP reflector should confirm that of mould