3‐D nonisothermal flow simulation model for injected pultrusion processes

Abstract

AbstractInjected pultrusion (IP) is an efficient process for high‐quality, low‐cost, high‐volume manufacturing of polymeric composites with relatively simple cross sections. This process was developed recently, and efforts to develop tools for model‐based design and optimization of this process have only just begun. This work focuses on developing a 3‐D nonisothermal computer simulation model for the IP process. First, the governing equations for transport of mass, momentum, and energy are formulated by using a local volume‐averaging approach. In turn, a computer simulation model of the IP process is developed using the finite‐element/control‐volume (FE/CV) approach. Specifically, the continuity equation and the conservation of momentum equation are solved using a Galerkin FE/CV technique. The chemical species balance equation is solved in the Lagrangian frame of reference, whereas the energy equation is solved using the streamline upwind Petrov‐Galerkin approach. Using the simulation model, the effect of fiber pull speed, reinforcement anisotropy, and taper of the die on the product quality was demonstrated. In addition a simple pulling‐force model was developed and integrated with the simulation model. Overall, the simulation model can be effectively used to design the die geometry and to optimize the operating conditions for a given product.