Numerical algorithm and adaptive meshing for simulation the effect of variation thickness in resin transfer molding process

Samir, Jamal; Echaabi, Jamal; Hattabi, Mohamed

doi:10.1016/j.compositesb.2011.03.027

Cited by 16 publications

(12 citation statements)

References 47 publications

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“…1 w e i d Xi ¼ 1; 2; 3; 4 (19) where c e 1 ¼ @h e @v e f @v e f @P e was calculated at the centroid of the element, e, by averaging the nodal values, w e i is the linear interpolation function, and X e is the domain of the element. Similarly, the stiffness matrix at each element was constructed using Dry and wet reinforcements are known to have different compaction characteristics due to the lubrication effect of resin on fibers and nesting of fiber bundles when they are wetted.…”

Section: Solution Of Resin Pressure Pmentioning

confidence: 99%

“…If a coarse mesh is used, the accuracy of this approach suffers because it cannot adequately capture the temporally varying properties (such as thickness, fiber volume fraction and permeability of the elements) during a time step. 17 To decrease the undesired mass imbalance, several researchers developed techniques by refining and/or adapting mesh [17][18][19] or by using floating nodes 20 which indirectly decrease time step size and thus obtain a more accurate solution. In this study, resin pressure evolution and flow front propagation are coupled by updating the pressure distribution and flow front location using a small time step (a time step smaller than the time required to completely fill a control volume at the flow front that will be filled the earliest) that results in similar computational benefits and complexity as the floating node approach presented in Govignon et al 20 For experimental investigation of evolution of part thickness distribution during VI, researchers employed various displacement sensors such as dial gauges [21][22][23][24] and non-contact laser sensors.…”

Section: Introductionmentioning

confidence: 99%

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Monitoring and modeling of part thickness evolution in vacuum infusion process

Caglar

Hancioglu

Sozer

2020

Journal of Composite Materials

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The main hurdles in Vacuum Infusion (VI) are the difficulty in achieving complete mold filling and uniform part thickness. This study integrates process monitoring by full field thickness measurements and resin flow modeling that accounts for compaction and permeability characterizations of fabric reinforcements to assess the evolution of part thickness during filling and post-filling stages of VI process. A Structured Light Scanning system is used for full field thickness monitoring in experiments and a Control Volume Finite Element Method solver is implemented to couple resin flow with fabric’s compaction and permeability. Two cases are studied both experimentally and numerically. Evolutions of thickness and pressure validate the developed flow solver, its accuracy in terms of predicting fill times and fill patterns, suitability and limitations of the elastic compaction models for thickness modeling.

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Section: Solution Of Resin Pressure Pmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Monitoring and modeling of part thickness evolution in vacuum infusion process

Caglar

Hancioglu

Sozer

2020

Journal of Composite Materials

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“…In order to guarantee simulation precision and broad applicability, the volume of fluid (VOF) module of the Fluent software, which has been widely used in the simulation of LCM processes, [30][31][32] is applied as the development environment to implement the above approach. User-defined functions (UDFs) are applied to handle the resin exchange between the master element and deformation slave element.…”

Section: Implementation Based On Fluentmentioning

confidence: 99%

Simulating the resin flow and stress distributions on mold tools during compression resin transfer molding

Yang

Jin

et al. 2014

Journal of Reinforced Plastics and Composites

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Compression resin transfer molding (CRTM) is an effective process for the manufacturing of composite parts with large size and high fiber content. The analysis of the resin flow and stress distributions can only be performed by directly solving the coupled flow/deformation equations, but it is difficult to handle the complicated preform deformation models and geometry models; therefore, the simulation precision and application range are extremely limited. In this paper, an alternative approach is introduced to overcome the above problems, in which the preform deformation and the accompanying resin release during the secondary compaction phase are calculated in an additional element associated with each unit of the discretized model geometry instead of solving the coupled governing equations directly, so the complex compaction models can be adopted. Three simulation examples are presented to demonstrate the accuracy and capability of the above numerical approach on velocity-controlled, force-controlled 3D CRTM processes.

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“…Increasing demands on the strength, stability and aerodynamic precision of many thin-walled aircraft structures made from polymer composite materials [ 1 , 2 , 3 ] have prompted a large amount of research into design methods [ 4 , 5 , 6 , 7 , 8 , 9 ] and technologies [ 10 , 11 , 12 , 13 ] capable of meeting these requirements at satisfactory performance and cost. An analysis of the results of these studies shows that in practice, meeting these often conflicting requirements with restrictions on mass, properties of available components and technologies is a rather complex task that can be solved by making expert decisions.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of Thin-Walled Polymer Composite Part Quality When Manufactured Using Vacuum Infusion with Various External Pressure Controls

Shevtsov,

Chang,

Zhilyaev

et al. 2024

Polymers

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The article presents the results of modeling various modes of vacuum infusion molding of thin-walled polymer-composite structures of arbitrary geometry. The small thickness of the manufactured structures and the fixation of their back surface on the rigid surface of the mold made it possible to significantly simplify the process model, which takes into account the propagation of a thermosetting resin with changing rheology in a compressible porous preform of complex 3D geometry, as well as changes in boundary conditions at the injection and vacuum ports during the post-infusion molding stage. In the four modes of vacuum-infusion molding studied at the post-infusion stage, the start time, duration and magnitude of additional pressure on the open surface of the preform and in its vacuum port, as well as the state of the injection gates, were controlled (open–closed). The target parameters of the processes were the magnitude and uniformity of the distribution of the fiber volume fraction, wall thickness, filling of the preform with resin and the duration of the process. A comparative analysis of the results obtained made it possible to identify the most promising process modes and determine ways to eliminate undesirable situations that worsen the quality of manufactured composite structures. The abilities of the developed simulation tool, demonstrated by its application to the molding process of a thin-walled aircraft structure, allow one to reasonably select a process control strategy to obtain the best achievable quality objectives.

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Numerical algorithm and adaptive meshing for simulation the effect of variation thickness in resin transfer molding process

Cited by 16 publications

References 47 publications

Monitoring and modeling of part thickness evolution in vacuum infusion process

Monitoring and modeling of part thickness evolution in vacuum infusion process

Simulating the resin flow and stress distributions on mold tools during compression resin transfer molding

Numerical Study of Thin-Walled Polymer Composite Part Quality When Manufactured Using Vacuum Infusion with Various External Pressure Controls

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