Abstract
Wet Compression Moulding (WCM) provides large-scale production potential for continuously fibre-reinforced structural components due to simultaneous infiltration and draping during moulding. Due to thickness-dominated infiltration of the laminate, comparatively low cavity pressures are sufficient - a considerable economical advantage. Similar to other Liquid Compression Moulding (LCM) processes, forming and infiltration strongly interact during process. However, the degree of forming is much higher in WCM, which disqualifies a sequential modelling approach. This is demonstrated in this work via experimental characterisation of the interaction between compaction and permeability of a woven fabric and by trials with a transparent double dome geometry, which facilitates an in situ visualization of fluid progression during moulding. In this light, and in contrast to existing form filling approaches, a forming-inspired, three-dimensional process simulation approach is presented containing two fully-coupled macroscopic forming and fluid-submodels. The combined model is successfully benchmarked using experimental double dome trials with transparent tooling.
Highlights
Wet Compression Moulding (WCM) provides high-volume produc tion potential for continuous fibre-reinforced components
Due to thickness-dominated flow progression and short infiltration distances within the mould, comparatively low cavity pres sures are sufficient, which makes the process attractive compared to conventional liquid composite moulding processes such as (Compres sion) Resin Transfer Moulding (RTM/CRTM) or Vacuum-assisted Resin Infusion (VARI)
Similar to the draping models, established modelling approaches are exploited in industrial applica tions for example as part of PAM-COMPOSITES (ESI-GROUP) for continuous reinforcements which covers most of the Liquid Compression Moulding (LCM) processes - except the WCM process
Summary
Wet Compression Moulding (WCM) provides high-volume produc tion potential for continuous fibre-reinforced components. The individual contribution and relevance of the involved mechanism varies during moulding In this regard, the tool stroke can be subdivided into three phases (cf Fig. 1). In the first approximately 85% of moulding (I), the partly pre-infiltrated textile stack is shaped. This phase is dominated by draping mechanisms which are related to the membrane, bending and interface behaviour of the partly infiltrated material. Relevant fluid pressure starts to emerge in some areas of the mould This coupled phase (II) is critical in terms of Fluid–Structure Interaction (FSI) since the stack is not fully constrained yet, but already locally exposed to increased fluid drag forces. In the following, related experimental and numerical studies are outlined with special focus on woven fabrics as this material is used in this study
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