Mold filling analysis in resin transfer molding

This study is a comparison of independently designed mold flow experiments performed at The Dow Chemical Company with simulations from a computer code developed at The Ohio State University. The experiments used in the validation study included isothermal 1-dimensional flow with line gating and end venting, isothermal 2-dimensional flow with converging flow and center venting, and two different resin systems. The simulation results were compared with experimental pressure and temperature readings and fill times. It was found that simulated fill times could be predicted within experimental error and pressure distributions could be predicted with the application of a scaling factor.     

In-plane permeability measurement and analysis in liquid composite molding

This work presents methods to measure and analyze in-plane permeabilities of various fabric reinforcements. The principal flow directions need to be determined first by conducting flow visualization. From the flow front pattern, the ratio of the permeabilities in the two principal directions can be determined. The pressure and the flow rate relationship from both radial and unidirectional flow measurement methods are then used to calculate the values of the permeabilities. By the use of the unidirectional flow measurement method, the edge flow effect can also be estimated.     

Simulation of cavity filling and curing in reaction injection molding

This report describes a procedure to stimulate the reaction injection molding process. The analysis considers the conversion that occurs during cavity filling with reactive fluids and the subsequent cure in the mold based on initial conditions derived from the filling analysis. Extensive conversion can occur during cavity filling when highly reactive resins are used. High conversion material with attendant high viscosity can be found in the cavity during filling without flow seizure because the conversion is non-uniform. The overall cycle time can be decreased by promoting conversion during cavity filling as long as flow seizure is avoided. Temperature and conversion profiles during cure in the mold elucidate thermal runaway and its importance in reaction injection molding. The simulation can be used to explore material and process parameter sensitivity, predict the cycle time and the maximum exotherm temperature, and evaluate moldability.     

On‐line mixing during injection and simultaneous curing in liquid composite molding processes

Liquid composite molding (LCM) processes such as resin transfer molding (RTM) and vacuum assisted RTM (VARTM) are used to manufacture high quality and net‐shape fiber reinforced composite parts. All LCM processes impregnate fiber preforms packed in a mold cavity with a thermoset resin. After the preform is fully saturated, the injection is discontinued but the resin continues to cure. Once the curing step is complete, the part is de‐molded. The resin has to be mixed with a curing agent to cure. Typically, the resin and the curing agent are mixed together in a pressure pot before the injection. This has several disadvantages, such as storage of large amounts of hazardous polymerizing resin, wastage, and cleaning of cured resin from the injection line. This paper proposes the implementation and calibration of an alternative to this technique. The approach is to mix the curing agent with the resin as the resin enters the mold through a separate system featuring two feed‐lines. Such a system will enable one to maintain a uniform gel time throughout the part by varying the mixing ratio of resin and the catalyst during the injection. An experimental study of such on‐line mixing to obtain simultaneous curing and to reduce the overall curing time is conducted and presented in this paper. Implementation of a control scheme that varies the curing agent during injection and its effect on cure time is benchmarked with the process in which the percentage of curing agent is held constant. The gel time for the fabricated parts was reduced by 20–25% by continuously varying the percentage of curing agent during injection. POLYM. COMPOS., 26:74–83, 2005. © 2004 Society of Plastics Engineers     

Mold filling analysis in vacuum-assisted resin transfer molding. Part II: SCRIMP based on grooves

Compared with SCRIMP based on the high-permeable medium, SCRIMP based on grooves has the advantage of a much higher mold filling rate. This paper analyzes the influences of various molding conditions on mold filling and presents models that can be used to predict the filling time and flow pattern in SCRIMP based on grooves. Mold filling experiments were carried out to investigate the effect of various factors such as the size of the groove, groove spacing, number of fiber layers and resin viscosity on mold filling. A leakage flow model was developed to simplify the simulation of the mold filling process in SCRIMP based on grooves. An “equivalent permeability” was introduced to represent the average flow capacity in the grooves. Compared with the Control Volume/Finite Element Method (CV/FEM) model, the leakage flow model greatly reduced computation time and yet provided simulation results that were in good agreement with experimental observations.     

Flow and cure phenomena in liquid composite molding

Liquid molding processes including resin transfer molding (RTM) and structural reaction injection molding (SRIM) continue to attract attention due to their potential for high volume manufacture. This paper examines and compares the pressuare and temperature histories observed in mold cavities during impregnation, heating, and polymerization for both RTM and SRIM using polyester, vinyl ester, and polyurethane resins in combination with continuous strand mats. Experimental results are related to thermal, chemical and rheological effects. Factors which influence materials behavior and process control and the implications for mold design are discussed.     

Spatially homogeneous gelation in liquid composite molding

On‐line mixing of the resin with its curing agents prior to injection into a mold is a common industrial technique for fabricating composite parts. For vinyl‐ester resins that cure via free radical polymerization, the concentrations of retarder, accelerator, and initiator are pre‐selected and cannot be changed during the injection. Hence, the resin that enters the mold the earliest has cured longer than the resin that enters the mold later, since the gel time for the resin is the same, owing to the fixed ratio of the curing agents. This approach leads to inhomogeneous cure of the resin and consequently to longer residence time of the resin in the mold. It requires an additional 50 to 75 percent of the filling time before a part can be de‐molded. In this study, it is shown that by adjusting the concentration of curing agents during the injection, a more homogeneous gel time throughout the mold can be achieved. The time to de‐mold is reduced to 18‐24 percent of the filling time. Sensors that measure the conductivity of the resin were used to detect the location and monitor the cure of vinyl‐ester. This approach could be extended to other resin systems to control the spatial curing of the resin in the mold.     

Fiber mat deformation in liquid composite molding. I: Experimental analysis

When a resin in injected into the mold in liquid composite molding, the preplaced fiber mat may deform near the inlet gate because of the high momentum carried by the injected fluid. A fiber free region near the gate followed by the fiber mat deformation may emerge. This phenomenon is most likely to occur when the stacked fiber mats have low permeability and the resin has high viscosity. A set of mold filling experiments were carried out using an instrumented metal mold and a small transparent mold to investigate the fiber mat deformation during mold filling. Experimental results showed that the fiber mat deformation was limited to a small region near the gate and that deformation greatly reduced the molding pressure. A forced fiber mat deformation employing a modified gate design was proposed to facilitate mold filling in liquid composite molding.     

Heat transfer and reaction issues in liquid composite molding

This paper surveys current issues in the modeling of heat transfer and chemical reaction in resin transfer molding and structural reaction injection molding. The discussion is organized around four steps of modeling: incorporating the physical phenomena into a model, gathering material data, analyzing the model to provide physical understanding, and solving the model for relevant cases. The local volume averaging approach is summarized as a method for deriving appropriate balance equations. The resulting equations are analyzed using dimensional analysis, and analytical solutions are presented for several special cases. These include steady heat transfer for small and large Graetz numbers, and a transient solution for heat transfer during filling at large Graetz numbers. This latter solution explains why preheating the fibers does not heat the resin uniformly. Numerical solution methods are discussed, with emphasis on upwinding techniques for hyperbolic problems. The paper concludes with a summary of research achievements and needs.     

Analysis of two-regional flow in liquid composite molding

This study investigates the two-regional flow in Liquid Composite Molding (LCM) with emphasis on the race tracking phenomenon. An equivalent permeability is introduced to describe the flow capacity in the fiber free region. A lumped permeability is also used to further simplify the flow modeling by averaging the flow across the flow direction. Both the equivalent permeability approach and the lumped permeability approach were verified with experiments. It is found that they are capable of modeling the race tracking effects in LCM.     

Mold filling analysis in vacuum-assisted resin transfer molding. Part I: SCRIMP based on a high-permeable medium

Mold filling in SCRIMP based on a high-permeable medium is complicated because of the considerable difference in the permeabilities of the fiber reinforcement, the peel ply and the high permeable medium. The objectives of this paper are to understand the flow mechanism through flow visualization experiments and to present models that can be used to predict the filling time and flow pattern. Permeabilities of a stitched fiber mat, a high-permeable medium and a peel ply were measured. Flow visualization of SCRIMP mold filling was carried out under various molding conditions. It was found that although the resin flowed faster in the high-permeable medium than in the fiber reinforcement, the flow front lead-lag was not very large and it remained nearly constant through the entire mold filling process. A three-dimensional Control Volume/Finite Element Method (CV/FEM) was adopted to solve the flow governing equations, i.e. the Darcy's law, and the influences of the flow properties of the high-permeable medium, the fiber reinforcement and the peel ply on filling time were investigated. Based on experimental observations and CV/FEM simulation, a simplified leakage flow model is also presented. The comparison of experimental and simulation results show good agreement.     

Experimental analysis and simulation of flow through multi-layer fiber reinforcements in liquid composite molding

Liquid composite molding (LCM) is a process in which a reactive fluid is injected into a closed mold cavity with preplaced reinforcement. Combined layers of different permeabilities are often used in LCM, which creates through thickness and inplane porosity and permeability variations. These inhomogeneities may influence the flow front profile in the thickness direction. To investigate the effect of the through thickness inhomogeneities, mold filling experiments were performed using preforms containing layers of two different fiber architectures. Aqueous corn syrup solutions were injected into a tempered glass mold containing the reinforcement stack. The progress of the flow front at various locations within the reinforcement was measured by an electrical conductivity technique based on the insertion of small wires between the reinforcement layers. Experimental data reveal the details of the flow front shape as the fluid penetrates the preform. Using these data, a model is proposed to calculate the overall in-plane permeability of the preform. Numerical simulations of the flow front progression performed with the computer software RTMFLOT developed in our laboratory are compared to the experimental flow front for various stacking arrangements. Results show good agreement between simulations and experiments and demonstrate the capability of the software to simulate multi-layer flow process.     

An interface‐update‐based implicit algorithm for mold filling simulation of liquid composite molding

In this article, a new implicit numerical algorithm has been presented for mold filling simulation in liquid composite molding process. The new implicit numerical algorithm is based on the update of flow interface to track flow front for each time step. Nodes of mesh are divided into three groups, i.e. filled nodes, interface nodes (or partially filled nodes), and empty nodes. Governing equations of filled nodes are solved to obtain pressure distribution; filling fractions of interface nodes are checked to determine if any node is needed to be added to filled nodes or be removed from filled nodes. The local LU factorization solver and preconditioned conjugated gradient iterative solver were employed to investigate the new implicit algorithm. Case studies demonstrated the performance of the proposed implicit algorithm. The new implicit algorithm reduced the computational complexity to below 2.0 power order of problem sizes. POLYM. COMPOS., 27:271–281, 2006. © 2006 Society of Plastics Engineers.     

Trans-plane fluid permeability measurement and its applications in liquid composite molding

This work discusses tow independent methods to measure and analyze the trans-plane fjuid permeability of various fiber reinforcements. In the unidirectional flow method, the measured injection pressure and flow rate, together with a one-dimensional Darcy's law were used to calculate the trans-plane permeability of fiber mats was independent of flow rate only at low injection pressure. Flow-induced fiber mat permeability change occurred when the injection pressure exceeded the clamping pressure. Measured permeability in conjunction with a three-dimensional mold filling computer program was used to simulate the effect of stacking sequence for a combination of different fiber mats on the mold filling pattern. Finally, a method is proposed to simplify the simulation of a three-dimensional flow through the fiber perform.     

Key issues in numerical simulation for liquid composite molding processes

Polymer-based composites have a great potential for the manufacture of energy-efficient vehicles. Because of this growing usage and also because mold cost increases with part complexity, numerical simulation of Liquid Composite Molding Processes such as Resin Transfer Molding (RTM) and Structural Reaction Injection Molding (SRIM) are becoming more important. To succeed in that venture, reliable input data as well as a numerical model able to simulate specific molding difficulties and complex shapes must be used. In this paper, several issues are discussed and a computer software is presented. Among them, permeability measurement is discussed. Concerning specific molding difficulties, simulation results compared with experimental data are presented for edge effects, flow in multilayers and flow in ribbed structures. Finally, nonisothermal filling is discussed. Experimental data showing how the temperature boundary layer is developed during the filling of a heated mold are presented.     

Modeling of void formation and removal in liquid composite molding. Part I: Wettability analysis

This two-part paper focuses on the characterization and simulation of two important molding defects in liquid composite molding—poor wetting and void formation. Part I analyzes resin-fiber wettability. This involved characterization of various liquids/resins and fiber filaments/fiber mats by using wicking test and capillary pressure measurement. Methodology to quantify capillary pressurewettability relationships was developed. It was found that the Leverett J function can correlate capillary pressure-saturation relationships for fiber reinforcements with various porosities and fiber architecture.     

Effect of fiber architecture on permeability in liquid composite molding

This study investigates the effect of fiber architecture on the permeability in liquid composite molding. The in-plane permeabilities of several glass fiber mats with different architectures were measured. A conceptual model based on the observed micro-scale flow pattern is proposed to explain the measured permeability results. It is found that the size of the pores outside the fiber tows and how these pores are connected determine the permeability of a fiber reinforcement.     

注塑成型充填过程的可压缩流动分析

注塑成型过程中,熔体在型腔中的流动和传热对制品质量性能有重要的影响.为了预测注塑制品的收缩、翘曲和力学性能,精确预测充填过程的流动及传热历史是十分必要的.本文考虑熔体的可压缩性及相变的影响,将充填过程中熔体的流动视为非牛顿可压流体在非等温状态下的广义Hele-Shaw流动.采用有限元/有限差分混合方法求解压力场和温度场,采用控制体积法跟踪熔体流动前沿,并应用Visual C++实现了注塑充填过程的可压缩流动分析.为了保证能量方程各项在单元内边界的连续性,结点能量方程各项由单元形心处的离散值加权平均获得,因而,能量方程在计算区域内整体求解.对两个算例进行了分析,模拟结果与实验结果的对比,验证了本文数值算法及程序.     

Fiber mat deformation in liquid composite molding. II: Modeling

Mathematical models are proposed to simulate the flow induced fiber mat deformation during liquid composite molding. The fiber bed is treated as an elastic beam and the load acting on the bed causes its deformation. The lubrication approximation is used to simplify the resin flow equation in the fiber free region, while Darcy's law is used to calculate the pressure and velocity fields in the deformed fiber bed. The governing equations are solved using the control volume/finite element method. The numerical results show reasonable agreement with the experimental results from Part I.