The paper proposes a novel approach to model the in-plane resin flow in deformable thin-walled fiber preforms for liquid composite molding processes. By ignoring the through-thickness flow in large scale thin-walled components, the 3-D resin flow is simplified to an in-plane flow inside the preform by a specialized divergence theorem. Shell kinematics are used to describe the fiber preform deformation, and the compressible flow is modeled in the context of the free surface flow in porous media. For simplicity and efficiency, the normal stretch, which is driven by the internal fluid and applied external pressure, represents the fiber preform expansion and compression. As compared with full 3-D models, the proposed shell model significantly reduces the problem size, while it still represents the primary physical phenomena during the process. The effects of neglecting the through-thickness flow are illustrated in a numerical example that compares the flow for a set of preforms with different thickness. The model is demonstrated from the numerical example of the mold filling in a doubly curved thin-walled fiber preform. Due to the applied vacuum and the consequent resin flow motion, the relevant deformation of the preform is observed.

This paper presents a novel porous media model for homogenized free surface flow, representing wet-out composites processing. The model is derived from concepts of homogenization applied to a compressible two-phase flow, accounting for capillary effects and the concept of relative permeability. Based on mass balance considerations, we obtain a nonlinear set of equations of convection-diffusion type involving the mixture (fluid) pressure and the degree of saturation as primary fields. A staggered Galerkin finite element approach is employed to decouple the solution. Moreover, the streamline upwind/Petrov-Galerkin technique is applied to attenuate the oscillations in the saturation solutions. The model accuracy and convergence of the finite element solutions are demonstrated through 1-dimensional and 2-dimensional examples, representing resin transfer molding flow processes. KEYWORDS free surface flow, partial saturation, porous media theory, process modeling, resin transfer molding Int J Numer Methods Eng. 2018;115:445-461.wileyonlinelibrary.com/journal/nme

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In this paper, recent shell model is advanced towards the calibration and validation of the Vacuum-assisted Resin Transfer Molding (VARTM) process in a novel way. The model solves the nonlinear and strongly coupled resin flow and preform deformation when the 3-D flow and stress problem is simplified to a corresponding 2-D problem. In this way, the computational efficiency is enhanced dramatically, which allows for simulations of the VARTM process of large scale thin-walled structures. The main novelty is that the assumptions of the neglected through-thickness flow and the restricted preform deformation along the normal of preform surface suffice well for the thin-walled VARTM process. The model shows excellent agreement with the VARTM process experiment. With good accuracy and high computational efficiency, the shell model provides an insight into the simulation-based optimization of the VARTM process. It can be applied to either determine locations of the gate and vents or optimize process parameters to reduce the deformation.

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