Modeling Flow in Compression Resin Transfer Molding for Manufacturing of Complex Lightweight High-Performance Automotive Parts

Abstract

Lightweight vehicles for energy savings encourages the use of composites in the new generation of vehicles. The compression resin transfer molding process (CRTM) is a novel variation of liquid composite molding (LCM) which offers fast manufacturing cycle for net-shape complex parts with excellent performance, ideal for the automotive industry. The process combines features of resin transfer molding (RTM) and compression molding. The process stages are identified and compared to other LCM processes to take advantage of existing simulation tools. A numerical model that simulates the resin flow in this process is proposed. Several first-order analyses are developed to estimate important process parameters to simplify modeling. Finally, this approach is used to model and simulate the process and is applied to a complex automotive part (the Automotive Composites Consortium B-pillar) with qualitative experimental validation.

Hybrid Structures Consisting of Sheet Metal and Fibre Reinforced Plastics for Structural Automotive Applications

“…In the series production of automotive structures, use is currently made of several variants of the resin transfer moulding (RTM) process [44]. Cycle times of about 10-15 min can be achieved with this manufacturing technology, depending on the dimensions of the structure.…”

“…These are placed in a heated mould. As the next step, the matrix resin is injected and then cured in the closed mould [36,44]. With the current RTM processes, it is not possible to manufacture hybrid structures in a single production step.…”

Simulating Mold Filling in Compression Resin Transfer Molding (CRTM) Using a Three-Dimensional Finite-Volume Formulation

“…Shojaei [13] developed a three-dimensional finite-element/control volume method to simulate the resin flow of a CRTM process in thick components, where a through-thickness impregnation can not be neglected. Furthermore Simacek et al [14] simulated CRTM also using a three-dimensional finite-element/control volume method focusing on the implementation of an open gap between the fibrous preform and the mold which is assumed to occur for wide mold openings. To the knowledge of the authors up to now is no three-dimensional two-phase CRTM simulation method available, which is based on a finite-volume formulation.…”

Investigating cavity pressure behavior in high-pressure RTM process variants

“…In this step, the preform is compacted to achieve the desired part thickness and fiber volume fraction. The part can be de-molded after the resin has cured [7]. Various studies have been conducted by different researchers to investigate the effect of certain process parameters on the quality of manufactured laminates by the CRTM, HP-CRTM and HP-IRTM processes [7][8][9].…”

“…The part can be de-molded after the resin has cured [7]. Various studies have been conducted by different researchers to investigate the effect of certain process parameters on the quality of manufactured laminates by the CRTM, HP-CRTM and HP-IRTM processes [7][8][9]. The co-authors have investigated HP-IRTM and HP-CRTM processes using different mold gaps and different laminate layups using carbon fibers to demonstrate the high volume production capability of the HP-RTM process variants.…”