Optimization of liquid resin infusion process (LRI) using finite element simulation software

Abstract

Infusion processes as LRI (Liquid Resin Infusion) can lead to a significant cost reduction but are not yet so widespread in aeronautical applications. Some of its advantages are: no need of autoclave, lower costs of materials, and the possibility of fabricating integrated structures that reduce the number of joints. However this process still presents some drawbacks such as the need to apply the "Test-Error" method or availability of extensive experience in the design of structures. The risk and cost associated with the infusion process is high, so the industry tends to use more conservative designs or adopt other less competitive alternative technologies and materials. For this reason, a simulation tool is essential to optimize the LRI process. In this work, the optimization and validation of a demonstrator of a wing box of an aircraft has been carried out using the PAM-COMPOSITES simulation software. Firstly, a geometric study and discretization of model has been carried out, secondly, the parameters that govern the process have been defined, and finally an analysis and validation of results have been carried out by means of a experimental infusion of the demonstrator. The obtained results have allowed us to control manufacturing times, improve injection and vacuum ports, and predict dry zones and front flow velocity. Simulations have allowed us to optimise the LRI process of the demonstrator, thus giving continuity to other studies on the viability of the infusion processes in primary structures in the aeronautical sector.