Influence of process parameters on resin content of filament-wound composite based on simulation of dual-phase resin flow

Abstract

Resin content in filament winding process is critical to the mechanical performance of the filament-wound composites. A numerical prediction model for the resin content was developed here through integration of three sub-models, viz., fibre random distribution model, permeability calculation model, and two-phase-flow model. This development enables the investigation not only on the effects of random arrangement of process parameters, but also on the prediction of resin content of filament-wound composites. In order to study the resin flow behaviour, the flow front was tracked based on the dual-phase model. Then, a serial of numerical simulations arranged by Box-Behnken Design method were conducted for both the random arrangement of the fibres and transverse media. Through an analysis of variance on the corresponding simulation results, it revelled pressure has the largest impact on resin content, followed by impregnation time, and resin temperature, in this order; resin flows much slower inner fibre tows than intra tows due to higher resistance of the fibre filaments inside the tows; and proper parameter combination should be specified to get the fibre tows fully saturated, like a pressure ranging from 30 to 40 N and impregnation time around 45 ms.