• Optimisation of structures, composite materials and production processes of manufacturing by mathematical simulation methods according to productivity, cost price and quality of products.
• Field research and definition of conditions for effective application of innovative solutions, materials and technologies in the composite field for every specific project
• Design of mathematical models of unexplored production processes, carrying out of numerical experiments and making recommendations for planning of practical introduction of new technologies

Mathematical Simulation of Production Processes

• PULTRUSION: Monitoring of internal stresses, range of temperatures and degree of curing;
• VACUUM INFUSION: Simulation, monitoring of cycle time and flow of resin in irregular zones;
• PRESS-MOULDING: Simulation of a geometry change due to pressure and shrinkage, monitoring of deformation modes

Mathematical model of bridge vacuum infusion process, developed in “STTC ApATeCh-Dubna”

Simulation example of the arched bridge impregnation	Impregnation of the arched bridge

Mathematical simulation of vacuum infusion

Goals:

• To predict impregnation time
• To prevent dry spots

Designs of the mathematical simulation department:

1. Program for mathematical simulation of the impregnation process by vacuum infusion.

The program allows

• To carry out numerical experiments on impregnation depending on location of resin inlets and degassing points
• To define the impregnation type, time and speed of a resin flow
• To make analysis of the deflected mode in a product
• To predict final properties of a product

2. Recommendations on experimental methods for defining parameters of the mathematical model.

Mathematical simulation of the seawall vacuum infusion process

“ApATeCh” specialists: Analyzed wave action and soil action Chose the protective coating Analyzed joints and irregular zones Tested specimens of materials and actual components Released design documentation Conducted mathematical simulation of the production process Introduced the mass production technologies

Mathematical simulation of pultrusion process

Goals:

• To prevent technological defects (cracks, buckling etc.)
• To keep the required geometry of a product
• Curing

Mathematical simulation:

• Heat expansion analysis
• Analysis of the curing process
• Defining the fields of stress and deformation

Adjustment of material properties and production process:

• Thermal and mechanical properties of a die and resin
• Kinetic parameters of curing
• Temperature of the die
• Speed of pulling out

Tasks:

• To combine the curing process with the speed of pulling out
• To adjust the components ratio in a composite product

Simulation of rods pultrusion at different pulling out speed

List of pultrusion profiles

Mathematical simulation of press-moulding

Goals:

• To prevent technological defects (cracks, buckling etc.)
• To keep the required geometry of a product
• Curing of resin
• To predict final properties of a product

Simulation:

• Heat expansion analysis
• Curing process
• Deflected mode of a composite during press-moulding
• Type of layers compression of the composite material
• Resin outflow

Recommendations:

• Components ratio in a composite product
• Kinetic parameters of curing
• Temperature of the press set-up
• Type and speed of press-mouldingя

Track superstructure

Simulation results of stress distribution during shrinkage