泡沫夹芯结构板泡沫壁流道内的流动特性

沟槽型真空辅助树脂传递模塑成型工艺（VARTM）是一种新型的泡沫夹芯结构板成型方法,利用实验探明了泡沫夹芯结构板芯材上不可渗泡沫壁流道内的流动行为。实验结果表明,液体在泡沫壁流道的流动能力大幅降低,只有光滑壁流道的60%左右,泡沫壁流道的粗糙内表面是造成这种现象的主要原因。提出了相应的压力驱动流动方程,并采用等效渗透率来表征液体在泡沫壁流道内的流动能力,得到了考虑粗糙表面影响的等效渗透率计算公式,提出了一个正确计算不可渗泡沫壁流道内流动的处理方法。     

Manufacturing and impact characterization of soy‐based polyurethane pultruded composites

Composites have several advantages such as high corrosion resistance, high strength to weight ratio, and lower maintenance costs over conventional materials. The major cost drivers for composites are raw materials and manufacturing process. Automated manufacturing processes like pultrusion and low cost raw materials can significantly lower the cost of composites. Polyurethane (PU) resin systems are commonly used in the pultrusion industry as they have higher performance characteristics and manufacturing feasibility when compared to conventional resin systems such as polyester and vinyl ester. Manufacturing cost can be further decreased by the use of bio‐based materials such as soy‐based resin systems. In the present work, solid pultruded panels have been manufactured using the base PU and two soy‐based PU resin systems. Pultruded panels were subjected to low velocity impact testing. Soy‐based PU resin systems showed comparable properties to that of the base PU resin system and is a viable alternative to the conventional petroleum‐based PU. POLYM. COMPOS., 35:1070–1077, 2014. © 2013 Society of Plastics Engineers     

Cost‐effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures

The advanced composite materials are increasingly being used in the automotives for their ultralight physical properties and super strong mechanical properties. This research examines the cost‐effective single‐step liquid resin infusion manufacturing process for developing all composite car body as the generally used sheet molding compound manufacturing process is highly capital intensive. Three different scaled down models of the Eco car were developed focusing on minimal weight and air drag coupled with aesthetics. Structural design and analysis was carried out using the Pro/E and Ansys tools. The Pro‐E model was scaled up to generate computer‐aided drafting drawings for tool development. Different stations were marked on the model and sliced virtually for development of pattern. Moreover, the mold was manufactured from carbon and glass/polyester composites for prototype manufacturing of the car body. This involved manual placement of desired number of carbon layers as preform on female side of the mold. The vacuum sucked the resin through a number of carefully selected entry ports which ensured effective resin distribution and impregnation. Polycarbonate wind shield was thermoformed in the convection oven according to streamlined geometry of car body and hinged. The car body was integrated with the compatible floor panels and accessories. The crumble zone shock absorber in the bumper was manufactured using successive layers of nomax honeycomb and polyvinyl chloride rigid foam to dampen the accidental shock. The car performed remarkably well in the Eco marathon race held at Malaysia, 35:97–104, 2014. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineers     

透波材料的优化设计

本文通过常规树脂基体、玻纤织物增强材料和蜂窝芯材等主要原材料之间的优化复合设计,开展单板、三夹层结构和五夹层结构各形式复合材料之间的制作、电性测试与分析,优化设计出了一种新型兼顾电性、力学性能的功能型五夹层复合结构透波材料,满足了高性能舰载雷达宽频带、高透波等电性指标要求,同时还满足了其高比强、刚度的力学指标要求,解决了传统型设计和材料通常无法满足其电性能、强刚度、低成本制作的矛盾。     

Experimental analysis and numerical modeling of flow channel effects in resin transfer molding

Composite manufacturing by Liquid Composite Molding (LCM) processes such as Resin Transfer Molding involve the impregnation of a net‐shape fiber reinforcing perform a mold cavity by a polymeric resin. The success of the process and part manufacture depends on the complete impregnation of the dry fiber preform. Race tracking refers to the common phenomenon occurring near corners, bends, airgaps and other geometrical complexities involving sharp curvatures within a mold cavity creating fiber free and highly porous regions. These regions provide paths of low flow resistance to the resin filling the mold, and may drastically affect flow front advancement, injection and mold pressures. While racetracking has traditionally been viewed as an unwanted effect, pre‐determined racetracking due to flow channels can be used to enhance the mold filling process. Advantages obtained through controlled use of racetracking include, reduction of injection and mold pressures required to fill a mold, for constant flow rate injection, or shorter mold filling times for constant pressure injection. Flow channels may also allow for the resin to be channeled to areas of the mold that need to be filled early in the process. Modeling and integration of the flow channel effects in the available LCM flow simulations based on Darcian flow equations require the determination of equivalent permeabilities to define the resistance to flow through well‐defined flow channels. These permeabilities can then be applied directly within existing LCM flow simulations. The present work experimentally investigates mold filling during resin transfer molding in the presence of flow channels within a simple mold configuration. Experimental flow frot and pressure data measurements are employed to experimentally validate and demonstrate the positive effect of flow channels. Transient flow progression and pressure data obtained during the experiments are employed to investigate and validate the analytical predictions of equivalent permeability for a rectangular flow channel. Both experimental data and numerical simulations are presented to validate and characterize the equivalent permeability model and approach, while demonstrating the role of flow channels in reducing the injection and mold pressures and redistributing the flow.     

Resin transfer molding process optimization using numerical simulation and design of experiments approach

The art of resin transfer molding (RTM) process optimization requires a clear understanding of how the process performance is affected by variations in some important process parameters. In this paper, maximum pressure and mold filling time of the RTM process are considered as characteristics of the process performance to evaluate the process design. The five process parameters taken into consideration are flow rate, fiber volume fraction, number of gates, gate location, and number of vents. An integrated methodology was proposed to investigate the effects of process prameters on maximum pressure and mold filling time and to find the optimum processing conditions. The method combines numerical simulation and design of experiments (DOE) approach and is applied to process design for a cylindrical composite part. Using RTM simulation, a series of numerical experiments were conducted to predict maximum pressure and mold filling time of the RTM process. A half‐fractional factorial design was conducted to identify the significant factors in the RTM process. Furthermore, the empirical models and sensitivity coefficients for maximum pressure and mold filling time were developed. Comparatively close agreements were found among the empirical approximations, numerical simulations, and actual experiments. These results were further utilized to find the optimal processing conditions for the example part.     

Use of genetic algorithms to optimize gate and vent locations for the resin transfer molding process

Resin infusion processes are finding increasing applications in the manufacture of composite parts that have geometric and material complexities. In such cases, the placement of gates and vents is non-intuitive and may require expensive repetitive experimentation. Finite element based resin flow simulation codes have been successfully used for modeling and analysis of the mold filling process. Such filling simulations, when coupled with a search algorithm, can also prove useful for optimal design of the filling process. Genetic algorithms (GAs) mimic natural selection and can efficiently “evolve” near-global optimal solutions from a large number of alternative solutions. In this paper, GAs are used to optimize gate and vent locations for the resin transfer molding process in order to minimize fill times and dry spot formation. A process performance index or cost function is defined that incorporates the fill time and dry spot formation as primary variables. A part having material and geometric complexities was chosen for a case study. A genetic algorithm and mold filling simulations were used interactively to search for optimal gate and vent locations to locate near optimal solutions. The GA was able to find good solutions using less than 1% of simulations of the possible permutations of gates and vents. The case study was also repeated in the presence of recetracking channels. Again, the optimal locations were found by the GA using less than 1% of all possible combinations. Thus, GAs can be efficiently used for minimization of fill time and dry spot formation through optimal location of gates and vents in RTM processes. However, the optimal location will be a function of the cost function, the choice of which depends on the trade-offs between different factors and the quality of the part desired.     

New data for sandwich panels on the correlation between the SBI test method and the room corner reference scenario

Assessment of the fire behaviour of sandwich panels is continuously under discussion. The fire behaviour of these panels is a combination of material characteristics such as the core material and mechanical behaviour of the panels such as joints, dilations etc. The use of small or intermediate scale tests can be questioned for such types of products. Within the proposed European product standard for sandwich panels (prEN 14509) the intermediate scale test method SBI (EN 13823) has been suggested as the fire test method to certify panels. The standard does, however, use quite an artificial mounting procedure, which does not fully reflect the end‐use conditions of the panels. In a previous research project conducted by Nordtest it was shown that the correlation between the SBI test method and both the ISO 9705 and ISO 13784 part 1 was insufficient. The test data produced for the SBI test method, however, did not use the above mentioned mounting technique. In this article new data for a number of products are added to the database using the mounting procedure of the product standard. The data are compared with the previous data and show that the mounting method of the product standard results in slightly more severe conditions but that there are still discrepancies with the full‐scale test results. The data also show an unacceptable level of repeatability due to the fact that small dilations result in a wide variation of classification result. The new data together with the old data show once more that it is dangerous to make a fire safety assessment of a sandwich panel based on small or intermediate scale tests. Copyright © 2004 John Wiley & Sons, Ltd.     

Influence of textile parameters on the in‐plane permeability characteristics of non‐crimped fabric preforms

Material parameters such as the permeability of dry reinforcing textiles are key variables for modern composite production using liquid composite molding (LCM) technique. Nowadays numerical filling simulations are required for predicting the mold filling behavior. Inaccurate predictions can lead to a high risk of air inclusion and corresponding need for cost‐intense revision of the mold design. Permeability values of the textiles used in the process are basic requirements for a numerical filling simulation, since the permeability is directly linked to the filling behavior. Nevertheless, the permeability values of non‐crimped fabrics (NCF) which are used for aerospace and automotive structures are rare. In this study the influence of textile parameters of NCF on the in‐plane permeability has been investigated using a capacitive in‐plane permeability measurement technology. The results show the influence of the roving filament number as well as the used stitch length on the in‐plane permeability. It is confirmed that the textile grammage is not affecting the in‐plane permeability of NCF reinforcements. The results of this study are valuable for textile selection with specific permeability data as well as for numerical filling simulations. POLYM. COMPOS., 37:1854–1863, 2016. © 2015 Society of Plastics Engineers     

Elevated‐temperature vacuum‐assisted resin transfer molding process for high performance aerospace composites

Vacuum‐assisted resin transfer molding (VARTM) is commonly used for general temperature applications (<150 °C) such as boat hulls and secondary aircraft structures. With growing demands for applications of composites in elevated temperature environments, significant cost savings can be achieved by employing the VARTM process. However, implementation of the VARTM process for fabricating elevated temperature composites presents unique challenges such as high porosity and low fiber volume contents. In the present work, a low cost and reliable VARTM process is developed to manufacture elevated temperature composites for aerospace applications. Modified single vacuum bagging infusion and double vacuum bagging infusion processes were evaluated. Details of the method to obtain high quality composite parts and the challenging issues related to the manufacturing process are presented. Density and fiber volume fraction testing of manufactured panels showed that high quality composite parts with void content less than 1% have been consistently manufactured. A property database of the resin system and the composites was developed. A three‐dimensional mathematical model has also been developed for flow simulation and implemented in the ABAQUS finite element package code to predict the resin flow front during the infusion process and to optimize the flow parameters. The results of the present study indicate that aircraft grade composite parts with high fiber volume fractions can be manufactured using the developed elevated temperature VARTM process. © 2013 Society of Chemical Industry     

Computational fluid dynamics applied to the vacuum infusion process

An all‐purpose computational fluid dynamics software is used for simulations of the vacuum infusion process. The study comprises simulations of a full three‐dimensional two‐phase flow through a porous medium. The medium that has an anisotropic, spatial‐ and time‐dependent permeability is located in a complex mold with moving boundaries. With this generalization, different material combinations, processing conditions, and even other manufacturing techniques can be evaluated. The strength of the presented approach is exemplified by simulations of mold filling of a real part, using a typical vacuum infusion set‐up. In addition to the overall development of the model, a number of specific aspects and phenomena are investigated and evaluated. Local lead of the flow front and a minor influence in overall flow front lead‐lag, with no influence on the fill time, is the result of simulations of edge effects due to poor preform fitting. POLYM. COMPOS., 26:231–239, 2005. © 2005 Society of Plastics Engineers     

Improvement of mechanical properties of structural thermoplastic composites using a reactive (low molecular weight) matrix component

An innovative manufacturing process for continuous fiber composites with the polymeric matrix made up of polypropylene and epoxy resin, as a model reactive low molecular weight component, was developed; variable process parameters give rise to different morphologies of matrix components surrounding the woven fabric reinforcement. Furthermore, the combination of both thermoplastic and thermosetting polymers permitted intimate fibers impregnation, typical of thermosetting matrix composites, with short process cycle time, which usually occurs in manufacturing process of thermoplastic matrix composites. Polypropylene (PP) films, glass fibers fabric, and epoxy resin film were used to produce flat composite through film‐stacking technique. The preparation process focused on control of both epoxy resin cure process and polypropylene melting. The process was able to induce the two matrix components to form either a planar (sandwich‐like) structure or a three‐dimensional (3D) network by means of controlling the process parameters such as pressure and heating rate. The strong enhancement of the mechanical properties (Young's modulus and tensile strength of the composites with the 3D structure were almost twice as high of those of the composites with sandwich‐like matrix structure) was due to the different microstructures produced by the interplanar flow of the thermoplastic polymer. POLYM. COMPOS., 31:1762–1769, 2010. © 2010 Society of Plastics Engineers.     

Numerical analysis of parametric effects on consolidation of angle‐bended composite laminates

In the previous study, the finite element formulation has been developed by our group based on two‐dimensional resin flow and fiber compaction model. Good agreement between simulations and experimental results was found under the one‐dimensional flow condition. In this article, the two‐dimensional model was used to simulate the consolidation of angle‐bended laminates with the convex tool in autoclave process. The effects of material properties on the consolidation were studied. It was found that the fiber bed shear modulus significantly affects the compaction behavior in the corner section of angle‐bended laminate, the fiber bed compaction property decide the laminate deformation, and the resin viscosity and fiber bed permeability affect the rate of laminate compaction and consolidation time. The angle‐bended T700/BMI QY8911‐Ilaminates were manufactured in autoclave process. The experimental data validate the numerical simulation method for the consolidation of the angle‐bended laminates. These results are greatly helpful for the optimization of processing parameters, improvement of composite parts quality, and reduction of the fabrication cost. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

LCM工艺中注射压力对纤维预成型体渗透率的影响

复合材料液体模塑成型技术(LCM)是一种高性能低成本先进复合材料制造技术,成型过程中干的纤维增强材料被反应性树脂浸渍.充模流动中纤维毡的渗透率是一个重要的参数,它综合反映了流动中树脂和纤维所有的相互作用.由于受很多因素的影响,渗透率值通常取决于工艺的特殊条件.本文采用径向流动法测试了纤维毡的面内渗透率,着重研究注射压力的影响.     

Experiments and numerical simulations of low‐velocity impact of sandwich composite panels

This article investigates the response of composite sandwich panel with Nomex honeycomb core subjected to low‐velocity impact and compression after impact (CAI) by using the methods of experiments and numerical simulations. Low‐velocity impact of sandwich panels at five energy levels is carried out to research the damage resistance and tolerance. A failure model based on Hashin failure criterion is implemented to model the intralaminar damage behavior of laminated plies in the numerical simulation. The cohesive zone model is used to simulate the delamination damage between adjacent laminated plies. The honeycomb core behavior is defined as an elastic–plastic material. Good agreements, in terms of contact‐force histories, damage shapes, and indentation depths of the sandwich panels, are observed between the experimental and numerical results. During CAI analysis, the damaged panels present a phenomenon of quick crack propagation from impact indentation location to each unloaded side after the structural strength reached. It is found that the in‐plane compressive strength of damaged sandwich panels is almost 25–35% reduction than that of undamaged panels. POLYM. COMPOS., 38:646–656, 2017. © 2015 Society of Plastics Engineers     

RFI工艺中有关树脂流动监测的研究

渗透率测量是树脂膜熔渗（阴）技术在复合材料设计和优化中最关键的条件。基于光导纤维视觉技术，通过纤维视觉传感器测量渗透率，能够在光强度下降的情况下探测出树脂的流动情况，这将易于我们在实际生产中在第一时间内准确的监测树脂的流动。     

树脂膜熔渗工艺及其数值分析方法

本文首先介绍了树脂膜熔渗RFI成型工艺的发展现状、技术原理、材料要求及工艺特点,然后重点阐述了RFI工艺过程的数值模拟方法,对如何建立能够反映RFI工艺过程中树脂流动、固化和热传递等物理化学现象的数学模型进行了讨论.RFI工艺过程涉及参数较多,单纯采用试验方法来研究各种参数变化带来的影响不仅耗时,而且也不经济,结合数值模拟方法对RFI工艺进行研究,可以减少盲目性和提高效率,从而为优化工艺参数提供理论依据.     

复合材料工型肋的RTM工艺模拟与优化

采用PAM-RTM模拟软件,对变截面工型肋结构零件进行RTM工艺注射方案设计。过程中,分别进行了6种注射方案的结果模拟,从注射方式、注射参数及注射口选择等方面进行方案设计,对注射过程中的压力分布、树脂浸润效果及注射时间进行比较,根据比较结果进行综合评定,最终得出了最优注射方案,并将结果用以指导工装设计,成型了验证零件。结果表明:采用计算模拟技术,可替代人工试验,进行工艺及工装方案设计与制造;工型肋的摆放位置对树脂的浸润趋势和注射时间影响较小,但注射口和注射方式选择对工型肋零件的影响很大,线注射方式及端部注射的浸润效果和效率要好于点注射及梢部注射。     

A prediction method on in‐plane permeability of mat/roving fibers laminates in vacuum assisted resin transfer molding

Vacuum assisted resin transfer molding (VARTM) is one of the promising manufacturing techniques for large‐scaled composite components with complex geometry, such as yachts or fishing vessels. To reduce the failure risk of production, numerical simulation of resin infusion process before manufacture is helpful. In general, basic characteristics of perform, such as permeability, need to be measured by experiments in practice. However, this experimental approach sometimes may be costly because specific types of fibers as well as preform with different layer numbers need individual experiments. This study first introduces the experimental procedure of measuring the permeability of reinforcements via Darcy's Law. On the basis of experimental observation of permeability of different layer order, we assumed that the change of the permeability in different experiments is mainly affected by the space provided by the fiber. Accordingly, an efficient prediction method based on the idea of “total porous space of the reinforcement” is proposed. It is shown that this method can give reference between prediction and experiments of the mat/roving fiber preform. Though the resin flowing is complex, this prediction gives a simple, macroscopic reference way for the injection characteristic of large‐sized ships, and consequently facilitates the numerical design work of composite structures manufactured by VARTM technique. POLYM. COMPOS., 27:665–670, 2006. © 2006 Society of Plastics Engineers     

Automation of the vacuum assisted resin transfer molding process for recreational composite yachts

The use of glass fiber reinforced plastics (GFRP) in large primary marine structures has noticeably increased due to their favorable stiffness, strength, durability, and manufacturability. However, GFRP construction can become cost‐prohibitive at the superyacht‐scale (36–60 m) as defects and labor intensiveness increase. In this paper, we presented an automated vacuum assisted resin transfer molding process (VaRTM) that can be integrated into an existing setup for manufacturing recreational composite yachts in the 49‐meter range. The objective of automating the system is to reduce defects and labor intensity. The developed automation system consisted of a controller, resin supply lines with valves, and infrared sensors. The control software, valves and sensors were custom developed. The system automatically monitors and adjusts resin flow in the mold in real‐time to mitigate flow front variations. The system was used to run three different scenarios common in marine composites manufacturing using VaRTM; a flat plate with consistent ply sequence, a flat plate with varying ply sequence, and a scaled yacht keel section. Results indicated that use of the automated setup improved overall evenness of resin flow and limited unwanted convergence compared to the traditional manual setup. Tensile testing indicated similar mechanical performance but greater variation in the manual sample. Voids were discovered in regions of flow convergence of the manual panel and reflected slightly more varied tensile properties as compared to automated panels. POLYM. COMPOS., 38:2411–2424, 2017. © 2015 Society of Plastics Engineers