Real-time monitoring of thermal processes by reduced-order modeling

Production of large thermoplastic composites parts is a challenging issue for today's industry. Automated tape placement appears to be an appealing process where a tape is placed and progressively welded on the substrate consisting in previously placed tapes. The desired properties and geometry are produced laying additional layers in different directions. The thermal process is significantly affected by many material and process parameters (laser power, velocity…). Moreover, heat conduction inside the part depends on contact resistances at inter-plies. Real-time monitoring techniques for such process are extremely valuable in industrial practice. This paper addresses the solution of the parametric thermal model for: (i) identification the source term distribution; (ii) identification of the contact thermal resistance; (iii) identification of consolidation defects, etc. All of this in real-time.Apart from the novel approach to compute temperature at one point in real time. This paper is also original because it uses the reciprocity principle for thermal equation. Moreover it proofs the reciprocity principle in thermal problem when working in frequency domain. For the first time a parameterized model reduction technique (Proper Generalized Decomposition) is used to evaluate an offline generalized transfer function for any frequency in the desired range. Obviously, real-time examples and applications are shown, moreover, some of them are presented for defect signature determination and others for inverse problems.As a result of this research ESI funds research in simulation-based automated tape placement