Abstract
Very short manufacture cycle times are required if continuous carbon fibre and epoxy composite components are to be economically viable solutions for high volume composite production for the automotive industry. Here, a manufacturing process variant of resin transfer moulding (RTM), targets a reduction of in-mould manufacture time by reducing the time to inject and cure components. The process involves two stages; resin injection followed by compression. A flow simulation methodology using an RTM solver for the process has been developed. This paper compares the simulation prediction to experiments performed using industrial equipment. The issues encountered during the manufacturing are included in the simulation and their sensitivity to the process is explored.
Highlights
The higher specific modulus of carbon composites materials offers light weighting opportunities over aluminium and steel for the automotive industry
Appl Compos Mater cycle times required by the automotive sector, fast curing resins and high pressure, high volume flow rates are needed in liquid moulding processes
Impingement mixing equipment similar to that used in the reaction injection moulding (RIM) and structural reaction injection moulding (SRIM) processes allows the resin to be injected at a high volume flow rate
Summary
The higher specific modulus of carbon composites materials offers light weighting opportunities over aluminium and steel for the automotive industry. In this sector, composite design proves cost effective when the part count of structures is significantly reduced, leading to large components with complex geometry. Composite design proves cost effective when the part count of structures is significantly reduced, leading to large components with complex geometry To manufacture these components at the volumes and UK. Appl Compos Mater cycle times required by the automotive sector, fast curing resins and high pressure, high volume flow rates are needed in liquid moulding processes. The resultant injection pressure to achieve the desired flow rate through the porous medium can be in excess of 200 bar, exceeding the capability of the equipment
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