Numerical Study on the Resin Transfer Molding Curing Process for Thick Composites Materials

The successful manufacture of thick composites is challenging since the highly exothermic nature of thermoset resins and limited temperature control make avoiding the onset of detrimental thermal gradients within the composite relatively difficult.This phenomenon is mainly caused by exothermic heat reactions.The so-called Michaud's model has been largely used in the literature to reduce the gap between experience and simulation with regard to the effective prediction of the temperature cycle in these processes.In this work,another solution is proposed to simulate the curing process for thick composites,namely preheating the resin to activate the curing reaction before resin injection into the mold.A good agreement between the experiment and the simulation is found.Moreover,in order to minimize the thermal gradient in the final composite,the thermophysical properties of the fiber and the torque(temperature,time)of the Plate have been varied leading to interesting results.

STUDY OF FLOW AND TEMPERATURE IN RESIN TRANSFER MOLDING PROCESS BY NUMERICAL MODEL

A mathematical model of resin flow and temperature variation in the filling stage of the resin transfer molding (RTM) is developed based on the control volume/finite element method (CV/FEM). The effects of the heat transfer and chemical reaction of the resin on the flow and temperature are considered. The numerical algorithm of the resin flow and temperature variation in the process of RTM are studied. Its accuracy and convergence are analyzed. The comparison of temperature variations between experimental results and model predictions is carried out for two RTM cases. Result shows that the model is efficient for evaluating the flow and temperature variation in the filling stage of RTM and there is a good coincidence between theory and experiment.

Filling Simulation of Three-dimension Braided Composite in Resin Transfer Molding

This paper measured permeability of three-dimension braided preform by radial technology. The results show that principal permeability tensor coincided with their braiding axial direction. The software of one dimensional flow filling mold was designed using Visual C++ language. Filling time is predicted and validated. The result showed that the filling time of the mold centerline agrees with the prediction value. The filling time of the mould edge is shorter than that of the prediction. An actual plate of 3D braided preform/ modified polyarylacetylene composite is produced according to prediction value and validation analysis.

Three-dimensional finite element analysis of process-induced residual stress in resin transfer molding process

A three-dimensional finite element analysis of process-induced residual stress in resin transfer molding (RTM) process is presented. The finite element method (FEM) was employed to solve the coupled equations involved in the transient heat transfer and the cure kinetics of the resin, and the distributions of internal temperature and cure degree of the composite at any instant time were obtained. The self-consistent field micro-mechanics model was used to predict the cure-dependent mechanical properties of the composites. Thermal expansion and cure shrinkage were included in the analysis. The thermo-elastic mechanical governing equations were solved using the incremental stress-strain relationship based FEM and the residual stress development was predicted. The present results were validated by the comparisons with the pertinent literature. The numerical example of a half cylinder was presented. The results show that it is necessary to carry out the three-dimensional analysis due to the complex distributions of temperatures, cure degrees and process-induced stress for thick parts, which can be predicted at any point within composite structures in the present analysis.

Non-isothermal Mold Filling and Curing Simulation for Resin Transfer Molding

A numerical model of 2.5D non-isothermal resin transfer molding simulation is developed for thin part based on the control volume/finite element method. The non-uniform temperature distribution and the heat generation during the filling stage are modeled with the lumped temperature system and the species balance. Numerical algorithm of the simulation are studied. The molding simulation for a part is performed to show the effectiveness of simulating filling time, temperature distribution and curing degree.

Numerical Simulation of Mold Filling in Resin Transfer Molding Using Isoparametric Method

The mold filling of RTM was simulated based on the control volume finite element method (CV/FEM). The formulat ion using isoparametric transformation was discussed in detail and a computation al code based on isoparametric technique was developed. The simulation results w ere compared with experimental data. Different isoparametric elements, quadrilat eral and triangular, were compared in the simulation.It demonstrates that the us e of bilinear quadrilateral isoparametric elements in simulating the process can produce a higher precision and cost a less time than the use of triangular ones .

Phenylethynyl-terminated Imide Oligomers Modified by Reactive Diluent for Resin Transfer Molding Application

To meet the processing requirements of resin transfer moulding(RTM)technology,reactive diluent containing m-phenylene moiety was synthesized to physically mixed with phenylethynyl terminated cooligoimides with well-designed molecular weights of 1500-2500 g/mol derived from 4,4’-(hexafluoroisopropylidene)diphthalic anhydride(6 FDA),3,4’-oxydianiline(3,4’-ODA)and m-phenylenediamine(m-PDA).This blend shows low minimum melting viscosity(<1 Pa·s)and enlarged processing temperature window(260–361℃).FPI-R-1 stays below 1 Pa·s for2 h at 270℃.The relationship between the molecular weight of the blend and its melting stability was first explored.Blending oligoimides with lower molecular weights exhibit better melting stability.Upon curing at 380℃for 2 h,the thermosetting polyimide resin demonstrates superior heat resistance(T_(g)=420-426℃).

3D Numerical Simulation of Non-isothermal Resin Transfer Molding Filling Process Using Unstructured Tetrahedron Mesh

We present a numerical formulation for resin flow based on the concept of quasi-steady state situation at the flow front. To be fit for complicated product shapes,we use the four-node unstructured tetrahedron mesh based on which the numerical formulation of temperature and degree of cure is developed. The validity of our method is established in the case where ffexible meshes are used. The results show that the numerical procedure,tested on known data,provides numerically valid and reasonably accurate predictions.

Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

A New Method to Track Resin Flow Fronts in Mold Filling Simulation of RTM Process

A new method to track resin flow fronts, referred to as the topological interpolated method (TIM), which is based onfilling states and topological relations of adjacent nodes was proposed. An experiment on the mould filling process wasconducted. It was compared with exact solutions and the experimental results, and good agreements were observed.Numerical and experimental comparisons with the conventional contour mathod were also carried out, and it showedthat TIM could enhance the local accuracy of flow front solutions with respect to the contour method when mergingflow fronts and resin approaching the mold wall were involved.

PREFACE

Preform permeability is an important process parameter in liquid injection molding of composite parts.This parameter is currently determined with time consuming and expensive experimental procedures.This paper presents the application of a back-propagation neural network to predicting fiber bed permeability of three types of reinforcement mats. Resin flow experiments were performed to simulate the injection cycle of a resin transfer molding process.The results of these experiments were used to prepare a training set for the back propagation neural network program.The reinforcements consisted of plain-weave carbon,plain-weave fiberglass,and chopped fiberglass mats.The effects of reinforcement type, porosity and injection pressure on fiber bed permeability in the preform principal directions were investigated.Therefore,in the training of the neural network reinforcement type,these process parameters were used as the input data.Fiber bed permeability values were the specified output of the program.As a result of the specified parameters,the program was able to estimate fiber bed permeability in the preform principal directions for any given processing condition.The results indicate that neural network may be used to predict preform permeability.

Rheological Behavior and Process Prediction of Low Viscosity Epoxy Resin for RTM

The rheological behavior of a low epoxy resin system-SR8100/SD8734 for RTM in aviation industry was studied with viscosity experiments. The dual-Arrhenius rheological model and the improved engineering viscosity model were introduced and compared with the experimental data. The results indicated that the viscosity in the earlier stage calculated by dual-Arrhenius model matched the experimental data. As rising to 400 m.Pas, the viscosity calculated by the improved engineering model was closer to the experimental data. The processing windows of the resin system for RTM were determined by combining the two models, which could predict the theological behavior of the resin system in a more credible way. 30-45 ℃ was the optimum processing temperature.

Prediction of the Enhanced Out-of-Plane Thermal Conductivity of Carbon Fiber Composites Produced by VARTM

The thermal conductivity of epoxy resin can be increased by a factor of eight to ten by loading with highly conductive particles. However, higher loadings increase the viscosity of the resin and hamper its use for liquid composite molding processes. Thus, the enhancement of the out-of-plane thermal conductivity of carbon composites manufactured by VARTM and accomplished by matrix filling is limited to about 250%. In order to derive higher increases in out-of-plane thermal conductivity, additional measures have to be taken. These consist of introducing thermally conductive fibers in out-of-plane direction of the preform using a 3D-weaving process. Measured out-of-plane thermal conductivities of 3D-woven fabric composites are significantly increased compared to a typical laminated composite. It has been shown that if introducing highly conductive z-fibers, the use of a particle filled resin is not necessary and furthermore should be avoided due to the manufacturing problems mentioned above. An existing analytical model was altered to predict the effective thermal conductivity as a function of the composite material properties such as the thermal conductivities and volume contents of fibers in in-plane and out-of-plane directions, the thermal conductivity of the loaded resin, the grid-density of the out- of-plane fibers, and material properties of the contacting material. The predicted results are compared with measured data of manufactured samples.

Effect of Bio-filler on Hybrid Sisal-Banana-Kenaf-Flax Based Epoxy Composites:A Statistical Correlation on Flexural Strength

This work deals with the investigation of the synergistic effect of bagasse ash with sisal-banana-kenaf-flax fibers reinforced epoxy composite for their flexural behavior.The composites with three combinations of hybrid fibers viz.sisal/kenaf(HSK),banana/kenaf(HBK),and banana/flax(HBF)with bagasse ash(BGA)as filler material are fabricated using vacuum bag assisted resin transfer molding.Experiments were conducted based on L27 orthogonal array to understand the influence of control factor viz.fiber volume,alkali concentration&BGA over output response.A'-ray micro computed tomography analysis was conducted over the developed sample to infer the uniform dispersion of fiber and filler material.The experimental results reveal that the addition of fiber up to 30 vol%depicts better strength and further addition results in a negative impact.Increasing in order of BGA decreases the flexural strength of the developed composites.

Multiphase Flow and Thermo-Mechanical Behaviors of Solidifying Shell in Continuous Casting Mold

The metallurgical phenomena occurring in the continuous casting mold have a significant influence on the performance and the quality of steel product.The multiphase flow phenomena of molten steel,steel/slag interface and gas bubbles in the slab continuous casting mold were described by numerical simulation,and the effect of electromagnetic brake（EMBR） and argon gas blowing on the process were investigated.The relationship between wavy fluctuation height near meniscus and the level fluctuation index F,which reflects the situation of mold flux entrapment,was clarified.Moreover,based on a microsegregation model of solute elements in mushy zone with δ/γ transformation and a thermo-mechanical coupling finite element model of shell solidification,the thermal and mechanical behaviors of solidifying shell including the dynamic distribution laws of air gap and mold flux,temperature and stress of shell in slab continuous casting mold were described.