Efficient stochastic simulation approach for RTM process with random fibrous permeability

An efficient numerical approach is presented for the simulation of mold filling process with random fibrous permeability as input. Suitable dimension-reduction techniques are employed to represent all the random fields in the physical system. The required accuracy in tracking the moving resin flow front is guaranteed by the Level Set Method (LSM). The Probabilistic Collocation Method (PCM) is applied in the efficient solution of the non-linear stochastic system. Numerical examples for different injection schemes are presented to demonstrate the cost-effectiveness of the current approach in predicting the variability in mold filling results in comparison to the traditional Monte Carlo Simulation (MCS).     

Correlation of void distribution to VARTM manufacturing techniques

Vacuum assisted resin transfer molding (VARTM) is a liquid composite molding (LCM) technique used to manufacture large scale composite structures. Fiber preforms are placed on a tool surface and covered by a flow enhancement layer and a plastic bag. A vacuum is drawn on the system to infuse the resin. When the resin does not fully saturate the empty regions in between the fibers, voids are created. The fiber tows in woven and stitched preforms have a much lower permeability as compared to the bulk permeability of the fabric. Hence, fiber tows saturate with resin later than the pores between fiber tows and are more prone to voids.This study explores the impact of extended resin bleeding time and additional flow resistance at the vent on the void content within fiber tows both experimentally and by numerical simulation. Samples were machined from each of the manufactured panels and analyzed using image analysis techniques to obtain a relative void content. The experimental results were compared to results obtained by numerical simulation.The experimental void distribution showed that if resin is not allowed to bleed or if no external resistance is attached at the vent, the void content over the length of the part is not uniform. All void levels reduced when resistance was added or bleeding was allowed. The discrepancy between experimental and numerical results was addressed by including deformable distribution media in numerical model to capture the continuation of resin flow after the injection gate is closed.     

基于VOF/PLIC界面追踪方法的RTM工艺充模过程数值模拟

针对基于Darcy定律的树脂传递模塑(RTM)工艺的充模过程数值模拟的局限性,将纤维预制体内的充填流动作为两相流(树脂相和空气相)处理,在动量方程中考虑了惯性项和粘性项,采用有限体积方法(FVM)离散控制方程,并与VOF/PLIC界面追踪方法相结合,发展了求解树脂在纤维预制体内非稳态流动问题的数值模拟方法.在此基础上开发了RTM工艺的充模过程数值模拟程序,其算例的数值模拟结果与解析解或实验结果吻合良好,验证了此数值模拟方法的有效性和可靠性.     

Mass conservation in numerical simulation of resin flow

The finite element/control volume (FE/CV) approach is commonly used for numerical simulation of resin flow in many composites manufacturing processes. The law of mass conservation is sometimes violated with the use of this approach. Especially, when the Galerkin formulation is used with isoparametric finite elements to obtain the pressure field, the balance of resin mass cannot be achieved.In this paper, reasons leading to such mass imbalance are investigated. A numerical model based on material incompressibility is developed to eliminate the problem. A few isothermal flow simulation examples are presented to demonstrate the application of the model. The results obtained are in excellent agreement with the analytical solutions.     

树脂传递模塑成型工艺中嵌套效应引起渗透率变异的实验与数值模拟

树脂传递模塑成型工艺(RTM)中最重要的变形模式之一是厚度方向压缩。厚度方向压缩减小了织物预成型体的厚度,使织物预成型体局部结构形式发生改变从而引起嵌套效应。嵌套效应不仅会减少织物预成型体的厚度,增加纤维的体积分数并改变孔隙率,而且相邻织物层嵌套效应具有一定的空间分散性,从而使得织物预成型体渗透率具有变异性。本文针对低黏度树脂设计了一种实验装置用以测量局部渗透率的空间分散性,随后建立了随机嵌套单胞模型,利用ANSYS/CFX有限元软件实现了单胞填充浸润的数值模拟,通过流量分析获得局部渗透率,并研究了渗透率的统计分布。通过实验结果与数值模拟结果相对比,验证数值模拟结果的可靠性。最后,基于渗透率的统计分布建立了随机渗透率场,并进行填充浸润的数值模拟,通过与传统恒定渗透率的方法进行比较,证明该方法具有更高的先进性。研究结果可以对未来RTM工艺的稳健性优化提供依据。      

基于小波包能量曲率差法的桥梁损伤识别试验研究

针对各种损伤识别指标中,小波包能量曲率差法仅有数值仿真、未经试验验证,尤其缺少实际工程验证问题,用数值模拟验证该方法识别结构损伤的有效性;利用沧州子牙河新桥替换下的梁体,进行两种工况损伤模拟。通过测试完好与损伤状态各点加速度响应,用小波包能量曲率差法识别损伤,考察小波函数和分解层数对识别效果的影响。结果表明,该方法有效,并可应用于实际工程。     

环氧树脂灌封结构固化行为数值模拟和工艺优化

依据实验测试获得E51环氧树脂的固化动力学和力学性能参数,针对特定尺寸的E51树脂灌封结构,将数值模拟与实验方法相结合,优化树脂的常温固化工艺为“二阶段”中高温固化工艺。首先采用数值模拟方法,分别比较第一段保温平台和第二段保温平台不同温度幅值和固化时间对结构内部的温度、固化度和应变的影响,优选固化工艺参数;然后基于光纤布拉格光栅(FBG)监测技术,对优选和原始固化工艺曲线的结构内部的固化温度和应变进行实时在线监测,结果表明了数值模拟的可行性,显示了通过数值仿真优选固化工艺曲线的可靠性;最后实验测试比较优选工艺和原始工艺曲线下制造的E51树脂浇注体性能,结果显示优选工艺制造的树脂浇注体的拉伸强度、压缩屈服强度、弯曲强度和冲击强度相比原始工艺制作的试样分别提高了3.9%、1.5%、14.5%和16.2%。      

用数值模型研究RTM工艺树脂流动规律

RIM成型过程中，树脂对纤维增强体的充分浸润是非常重要的一环。本文对树脂流动过程的特点进行了研究，建立了树脂流动控制方程。采用贴体坐标/有限差分法模拟了不同时刻树脂流动前沿曲线，计算结果与其他研究成果吻合良好。     

复合材料厚壁连杆RTM成型工艺模拟及制造验证

根据复合材料的可制造性及RTM成型工艺的特点对复合材料厚壁连杆的几何外形进行了优化设计。测定了纤维预成型体的渗透率参数, 采用数值模拟技术研究其RTM成型工艺过程, 并根据RTM流动模拟结果设计了成型模具, 成功地利用RTM工艺制备了复合材料厚壁连杆样件。对样件的力学试验考核表明, 采用基于数值模拟技术的工艺设计能够很好地满足制件的制造及载荷要求。     

Influence of meshing on the numerical simulation of liquid composite molding processes

Computer simulation has been an efficient and cost-effective tool for the Liquid Composite Molding (LCM) processes, including the RTM, VARTM, and resin infusion, compared to trial-and-error. The Control Volume Finite Element Method (CVFEM) has been the predominant method for simulation. Two critical issues of CVFEM are simulation accuracy and computational efficiency, and they are strongly dependent on meshing. In this paper, the influence of meshing on the simulation accuracy is investigated. Both uniform and non-uniform meshes are studied. The results show that for a radial flow, simulation accuracy can be significantly improved by using non-uniform meshes. A case study is conducted and it is shown that for a point injection, the computation time for mold filling simulation can be reduced by more than 99% while maintaining the same simulation accuracy.     

Simulation of the three-dimensional non-isothermal mold filling process in resin transfer molding

Numerical simulation of resin transfer molding (RTM) is known as a useful method to analyze the process before the mold is actually built. In thick parts, the resin flow is no longer two-dimensional and must be simulated in a fully three-dimensional space. This article presents numerical simulations of three-dimensional non-isothermal mold filling of the RTM process. The control volume/finite element method (CV/FEM) is used in this study. Numerical formulation for resin flow is based on the concept of nodal partial saturation at the flow front. This approach permits to include a transient term in the working equation, removing the need for calculation of time step to track the flow front in conventional scheme. In order to compare the results of the nodal partial saturation concept with the conventional method, a numerical scheme based on the quasi-steady state formulation is also presented. The computer codes developed based on both numerical formulations, allow the prediction of flow front positions; and pressure, temperature and conversion distributions in three-dimensional molds with complicated geometries. The validity of the two schemes is evaluated by comparison with analytical solutions of simple geometries. In all instances excellent agreement is observed. Numerical case studies are provided to demonstrate the effectiveness of the developed computer codes. The results show that the numerical procedure based on the nodal partial saturation concept, developed in this study, provides numerically valid and reasonably accurate predictions.     

基于谱元法的复杂地形风场大涡模拟

以Askervein山为研究对象,基于开源平台Nek5000,自编程序完成复杂地形下谱元法的网格建模,添加计算湍流粘性项子程序,对复杂地形风场进行大涡模拟,并与场地实测数据及其它数值结果进行对比。结果表明,谱元法的大涡模拟结果与Askervein山的场地实测结果符合较好,表明该方法在复杂地形风场的预测上有较高的精度,可用于复杂地形的风能资源评估。     

拆除爆破研究中数值分析方法的比较与选择

概述了数值分析法的分类。介绍了平面杆系有限元法、离散元法、数值流形法和不连续变形分析等几种数值分析方法。简单地讨论了平面杆系有限元法的分析步骤以及在拆除爆破中适于解决的问题 ;同时叙述了流形分析中采用的有限覆盖技术。通过分析和比较这几种方法在拆除爆破研究中的应用 ,作者认为 ,当前应用传统的有限元法进行爆破理论研究或拆除爆破模拟存在一些困难 ;离散元法用于拆除爆破理论的研究是可行的 ;不连续变形分析法对于拆除爆破模拟研究是一种具有良好前景的数值方法     

拆除爆破研究中数值分析方法的比较与选择

概述了数值分析法的分类。介绍了平面杆系有限元法、离散元法、数值流形法和不连续变形分析等几种数值分析方法。简单地讨论了平面杆系有限元法的分析步骤以及在拆除爆破中适于解决的问题 ;同时叙述了流形分析中采用的有限覆盖技术。通过分析和比较这几种方法在拆除爆破研究中的应用 ,作者认为 ,当前应用传统的有限元法进行爆破理论研究或拆除爆破模拟存在一些困难 ;离散元法用于拆除爆破理论的研究是可行的 ;不连续变形分析法对于拆除爆破模拟研究是一种具有良好前景的数值方法     

RTM成型复合材料T型接头工艺参数优化与力学性能实验研究

对树脂传递模塑(RTM)成型的复合材料T型接头进行了工艺参数优化、制备及力学性能实验研究。应用流动模拟软件,对RTM成型的复合材料T型接头进行了基体流动数值模拟,确定模具最佳注射方式和出胶口位置,并优化了影响树脂充模时间的工艺参数,显著提高了RTM接头的工艺性能。根据优化工艺参数结果,制备了RTM成型的复合材料T型接头试样,并进行了拉伸和压缩试验,分析了其破坏机制。根据拉伸和压缩试验现象和结果,发现RTM成型的复合材料T型接头拉伸破坏模式主要为富树脂三角区的树脂与纤维布界面分层,其拉伸破坏主要取决于树脂基体抗剥离分层的拉伸强度;压缩破坏模式为底板中央部位的弯曲分层与折断,其压缩破坏由接头底板中的纤维布抗拉强度决定;T型接头的压缩破坏强度高于拉伸破坏强度。     

大厚度复合材料曲面典型构件的工艺优化

大厚度复合材料的数值仿真存在缺乏实尺度验证、数值模型待优化等问题。本文针对真空辅助树脂传递模塑成型的大厚度复合材料曲面构件,通过大型风电叶片主梁的工艺仿真与实尺度实验验证,进行了工艺设计与工艺参数模型预测。首先对比研究了不同的工艺仿真方案;然后利用所选优化方案对树脂灌注方案进行工艺设计,并进行了实验验证;最后,提出了不同厚度制件的工艺参数预测模型。结果表明:所选优化方案可同时得到理想的计算效率和流动模拟结果;所设计工艺方案与实验吻合性良好;工艺参数预测模型所得结果与模拟结果基本一致。      

An efficient solver of the saturation equation in liquid composite molding processes

A major issue in Liquid Composite Molding Process (LCM) concerns the reduction of voids formed during the resin filling process. Reducing the void content increases the quality of the composite and improves its mechanical properties. Most of modeling efforts on process simulation of mold filling has been focused on the single phase Darcy’s law, with resin as the only phase, ignoring the formation and transport of voids. The resin flow in a partially saturated region can be characterized as two phase flow through a porous medium. The mathematical formulation of saturation in LCM takes into account the interaction between resin and air as it occurs in a two phase flow. This model leads to the introduction of relative permeabilities as a function of saturation. The modified saturation equation is obtained as a result, which is a non-linear advection-diffusion equation with viscous and capillary phenomena. In this work, a flux limiter technique has been used to solve a modified saturation equation for the LCM process. The implemented algorithm allows a numerical optimization of the injected flow rate which minimizes the micro/macroscopic void formation during mold filling. Some preliminary numerical results are presented here in order to validate the proposed mathematical model and the numerical scheme. This formulation opens up new opportunities to improve LCM flow simulations and optimize injection molds.     

Compressible flow analysis of filling and postfilling in injection molding with phase-change effect

In order to predict the shrinkage, warpage and mechanical properties of the injection molded parts, it is necessary to know the history of the flow field during injection-molding processes. In the present investigation a numerical simulation program was developed to predict the flow field in filling and post-filling stages of injection molding. To simulate the real molding conditions more accurately, a generalized Hele-Shaw model for a non-Newtonian fluid was assumed considering the effects of phase change and compressibility of the resin. A finite-element-finite-difference (FEM-FDM) hybrid scheme with control volume approach was employed as the solving technique. For modeling the viscosity of the resin, a modified Cross model was used with a double-domain Tait equation of state being employed in describing the compressibility of the resin during molding. The energy balance equation, including latent-heat dissipation for semicrystalline materials, was solved in order to predict the solidified layer and temperature profile in detail. For verification of the numerical results obtained from the developed program, the simulation results were compared with the experimental results obtained from the test mold set designed in the current study using commercial-grade PP and the data available in the literature. Based on a comparison between experiments and simulations, it was found that the currently developed program was useful in unified simulations of filling and post-filling in injection-molding processes when considering the phase-change effect.     

RTM工艺树脂流动过程数值模拟及实验比较

树脂充模是RTM工艺成型过程中的重要一环。研究了RTM工艺树脂流动过程的特点,建立了树脂渗流控制方程。采用贴体坐标/有限差分法模拟了树脂渗流过程,给出了不同时刻树脂流动前沿曲线及终止时刻压力场分布,计算结果与试验结果吻合良好。     

圆柱绕流气动噪声数值分析

为了快速预测刚性圆柱绕流的气动噪声,研究了一种将离散涡方法(DVM)和涡声理论结合起来计算低马赫数、高雷诺数流场气动噪声的方法。首先用Oseen粘性涡模型改进了离散涡方法并模拟了圆柱绕流,分析结果与实际情况相符。根据流场计算的结果,应用涡声理论进一步计算了远场的声压。测点的总声压级与实验值及其他数值计算结果都比较吻合。最后绘制了声场的指向性特性曲线,表明圆柱绕流声场明显的偶极子特性。