Unsteady Disposable Flow Tracking Using Discrete Phase Model

Abstract

Thermosetting materials are commonly used as an insulative material in medium- and high-voltage applications. Production of large volume elements is causing several problems related to a mold filling or an exothermic polymerization reaction, which may lead to quality issues. To improve the quality, numerical simulations are commonly used for a production process prediction and optimization. One of most critical stage of production of thermosetting-based components is filling the mold with a fresh, uncured resin. Laminar flow has a tendency to create sharp transitions between resin’s layers with different curing degree, which may lead to local mechanical weakening of the material or degradation of its insulative properties. Another problem observed during the material injection is creation of voids, having great influence on mechanical and electrical properties of the final product. A novel approach to the resin residence time tracking has been proposed, where a volume of fluid and a discrete phase method has been coupled. It allows to connect injection time and place of residence of the resin, even if it is a mixture of resins injected in various moments of the filling process. These methodologies are also applicable for design of product made of a functional materials based on different resin compounds or a microencapsulation.