Abstract
Light-weight structural components are increasingly made of continuous fiber reinforced plastics (CoFRP), but their mass production is still very expensive. Because of its high automation potential, especially the Compression Resin Transfer Molding (CRTM) process gains more and more attention. Numerical mold filling simulations help to optimize this process and can avoid expensive experimental studies. Here, we present a new method to simulate mold filling in CRTM using a full three-dimensional finite-volume (FV) method. In comparison to known finite-element (FE) methods, it contains a compressible two-phase/Volume-of-Fluid description of the air- and resin-phase. This approach is combined with a moving mesh to account for the change of cavity height during the process, which results in a change of fiber volume fractions and thus permeabilities. We verify the method by comparison to analytic solutions of the Darcy equation and to solutions of state-of-the-art mold filling simulation software. The presented method enables CRTM mold filling simulation of complex parts, which is shown in two application examples. Furthermore, this shows the potential of using FV-based tools to simulate mold filling in RTM process variants containing non-constant cavity geometries.
Highlights
The use of continuous fiber reinforced plastics (CoFRP) is significantly increasing in the aerospace and the automotive industry because of their excellent weight-specific mechanical properties
We present a new possibility to simulate mold filling of Compression Resin Transfer Molding (CRTM) based on a three-dimensional finite-volume discretization
The results shall emphasize the possibilities of this method to simulate the resin flow in CRTM for sandwich components including core materials, which is so far not possible by using state-of-the-art mold filling simulation software
Summary
The use of continuous fiber reinforced plastics (CoFRP) is significantly increasing in the aerospace and the automotive industry because of their excellent weight-specific mechanical properties. More and more process variants like Compression-RTM (CRTM) are used In this RTM variant, the mold is not fully closed when the resin is injected, which improves the infiltration behavior of the fibrous reinforcement. When the appropriate amount of resin is injected, the mold starts to close until the final part thickness is reached and the component is completely infiltrated This two-step process can help to minimize cycle time or reduce cavity pressure [10]. Shojaei [13] developed a three-dimensional finite-element/control volume method to simulate the resin flow of a CRTM process in thick components, where a through-thickness impregnation can not be neglected. A compressible formulation of the air phase was implemented to predict the development, movement and dispersion of air bubbles, which is not possible with finite-element based commercial RTM mold filling simulation software. The results shall emphasize the possibilities of this method to simulate the resin flow in CRTM for sandwich components including core materials, which is so far not possible by using state-of-the-art mold filling simulation software
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