Numerical simulation of injection/compression liquid composite molding. Part 2: preform compression |
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| Affiliation: | 1. Department of Mechanical and Industrial Engineering, University of Illinois, 1206 W. Green St., Urbana, IL 61801, USA;2. Polymer Composites Group, Polymers Division, Building 224, Room B108, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA;1. School of Materials Science and Engineering, Beihang University, Beijing 100191, PR China;2. National Key Laboratory of Advanced Composites, Beijing Institute of Aeronautical Materials, Beijing 100095, PR China;1. Engineering Design and Advanced Manufacturing, MIT Portugal Program, Faculty of Engineering, University of Porto, Porto, Portugal;2. Brussels Airlines Maintenance & Engineering, Belgium;3. Department of Materials Engineering, KU Leuven, Leuven, Belgium;4. INEGI-Institute of Science and Innovation in Mechanical and Industrial Engineering, Campus FEUP, Porto, Portugal;1. Department of Textiles, Ghent University, Technologiepark-Zwijnaarde 907, B-9052, Zwijnaarde, Belgium;2. Department of Materials Science and Engineering, Ghent University, Technologiepark-Zwijnaarde 903, B-9052, Zwijnaarde, Belgium;3. Laboratoire PRISME EA 4229, Univ. Orléans, Polytech Orléans, 8 Rue Léonard de Vinci, F-45072, Orléans, France;4. UGCT – Deparment of Physics and Astronomy, Ghent University, Proeftuinstraat 86, 9000, Ghent, Belgium;1. AI and Mechanical System Center, Institute for Advanced Engineering, Yongin, Kyonggi-Do 17180, Republic of Korea;2. School of Mechanical Engineering, Chung-Ang University, 221, Huksuk-Dong, Dongjak-Gu, Seoul 06974, Republic of Korea |
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| Abstract: | In the injection/compression liquid composite molding process (I/C-LCM), a liquid polymer resin is injected into a partially open mold, which contains a preform of reinforcing fibers. After some or all of the resin has been injected, the mold is closed, compressing the preform and causing additional resin flow. This paper addresses compression of the preform, with particular emphasis on modeling three-dimensional mold geometries and multi-layer preforms in which the layers have different mechanical responses. First, a new constitutive relation is developed to model the mechanical response of fiber mats during compression. We introduce a new form of nonlinear elasticity for transversely isotropic materials. A special case of this form is chosen that includes the compressive stress generated by changes in mat thickness, but suppresses all other responses. This avoids the need to model slip of the preform along the mold surface. Second, a finite element method, based on the principle of virtual displacement, is developed to solve for the deformation of the preform at any stage of mold closing. The formulation includes both geometric and material nonlinearities, and uses a full Newton–Raphson iteration in the solution. An open gap above the preform can be incorporated by treating the gap as a distinct material layer with a very small stiffness. Examples show that this approach successfully predicts compression in dry preforms for three-dimensional I/C-LCM molds. |
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