Heat Transfer Analysis in Double Diaphragm Preforming Process of Dry Woven Carbon Fibres

Srikara Dandangi, Sadegh Ghanei, Mohammad Ravandi, Jamal Naser () and Adriano Di Pietro
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Srikara Dandangi: Aerostructures Innovation Research Hub (AIR Hub), Swinburne University of Technology, Melbourne, VIC 3122, Australia
Sadegh Ghanei: Aerostructures Innovation Research Hub (AIR Hub), Swinburne University of Technology, Melbourne, VIC 3122, Australia
Mohammad Ravandi: Aerostructures Innovation Research Hub (AIR Hub), Swinburne University of Technology, Melbourne, VIC 3122, Australia
Jamal Naser: Department of Mechanical Engineering and Product Design Engineering, Swinburne University of Technology, Melbourne, VIC 3122, Australia
Adriano Di Pietro: Aerostructures Innovation Research Hub (AIR Hub), Swinburne University of Technology, Melbourne, VIC 3122, Australia

Energies, 2025, vol. 18, issue 6, 1-27

Abstract: Double diaphragm forming (DDF) represents an efficient manufacturing technique leveraging vacuum pressure and heat to form composite material stacks between flexible diaphragms. This study focuses on the critical role of thermal management during preforming, essential for material integrity, defect mitigation, and process efficiency. A comprehensive three-dimensional finite element model (FEM) is developed to investigate the heat transfer dynamics in DDF, incorporating temperature-dependent material properties such as specific heat and thermal conductivity under compaction and varying density conditions. A novel approach is introduced to predict thermal contact conductance (TCC) across multilayer carbon fabric interfaces, validated using four laminate configurations. The resulting effective thermal conductivity of the laminates is applied in production-scale simulations, enabling accurate predictions of temperature distributions, which are corroborated by experimental data. The findings highlight the significant impact of mesoscale interactions, such as yarn-level deformation and surface asperities, on TCC variation. The study provides an enhanced understanding of heat transfer mechanisms in DDF, offering insights to optimise process parameters, improve product quality, and advance manufacturing capabilities for complex geometries.

Keywords: woven carbon fabrics; double diaphragm preforming; heat transfer analysis; finite element modelling; thermal contact conductance (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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