Computational fluid dynamics in RTM method of the carbon composites molding

Abstract

The article focuses on simulating flow of epoxy resin in injection mold with carbon fiber fabric inside. Performed simulations were based on the process of manufacturing composite elements using modern RTM method. RTM method is used in production of high-end and sports car parts, and other lightweight products requiring high strength. It consists in injecting the resin under pressure into a closed mold with reinforcement. One of major problems in this method is providing adequate flow of the resin in injection mold and a complete supersaturation of reinforcement with a thermosetting resin. These aspects depend strongly on the direction of the fibers in the carbon fabric and porosity of the reinforcement. Information about proper construction of the mold and influence of fiber orientation and porosity can be obtained by numerical simulations using CFD commercial software Moldex3D. Research was based on actual process of manufacturing car mirror covers. Analysis of obtained results focused on the impact of changes in process input parameters. In particular, parameters such as the porosity and direction of fibers in the reinforcement were investigated. Test results are compared in terms of the degree of reinforcement supersaturation in the mold. Based on performed tests, appropriate conclusions were drawn.