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

Seuffert, Julian; Kärger, Luise; Henning, Frank

doi:10.3390/jcs2020023

Cited by 12 publications

(10 citation statements)

References 20 publications

(25 reference statements)

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“…In this case the OpenFOAM software is used, which employs a finite volume (FV) approach to solve the Navier-Stokes-Equations. Darcy's law is added as a source term to the momentum equation [20]. Therefore, the matrix is modeled as a quasi incompressible liquid phase and the air as a compressible gas phase [28].…”

Section: Fluid Mechanics and Numerical Methodsmentioning

confidence: 99%

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Experimental and Numerical Analysis of Mold Filling in Rotational Molding

et al. 2021

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This work focuses on the development of a numerical mold filling simulation for the rotational molding process. In the rotational molding process, a dry fiber preform is placed in a mold and impregnated with a thermoset matrix under rotation. Additionally, metallic load introduction elements can be inserted into the mold and joined with co-curing or form-fit, resulting in hybrid drive shafts or tie rods. The numerical model can be used to simulate the impregnation of the preform. Based on the resin transfer molding process, an OpenFOAM solver is extended for the rotational molding process. Permeability, kinetic and curing models are selected and adapted to the materials used. A wireless measurement solution with a capacitive sensor is developed to validate the model. Comparisons between measurements and numerically calculated impregnation times to reach the capacitive sensor with the matrix show good quality of the developed model. The average deviation between calculated result and measured mean values in the experiment is 43.8% the maximum deviation is 65.8% . The model can therefore be used to predict the impregnation progress and the curing state.

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Section: Fluid Mechanics and Numerical Methodsmentioning

confidence: 99%

“…The current state of research shows different approaches for numerical modeling the LCM processes such as VARI [15,16] or RTM [17][18][19][20][21]. As with analytical calculations, Darcy's law is used.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analysis of Mold Filling in Rotational Molding

et al. 2021

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“…This leads to a change of the simulation domain during mold filling. One possibility to simulate CRTM is using a FV based flow simulation combined with a dynamic simulation mesh, as proposed by the authors [236]. When furthermore an open gap above the preform occurs, the mold filling simulation has to be mod elled as a combination of a Darcy flow inside the preform and a Stokes flow in the open gap.…”

Section: Simulation Of Injection Processesmentioning

confidence: 99%

Fast processing and continuous simulation of automotive structural composite components

Henning

Kärger

Dörr

et al. 2019

Composites Science and Technology

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109

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Due to application-specific tailoring, continuous fiber reinforced plastics (CoFRP) provide an exceptional lightweight potential and are particularly suited for structural components. The use of CoFRP specifically for weight reduction of the automotive car body is the major focus of this feature article. Automotive mass production requires fast and qualified, thus highly automated and material efficient manufacturing technologies. Consequently, CoFRP manufacturing for automotive differs considerably from conventional CoFRP manufacturing for aerospace, particularly in terms of higher throughput with higher investment, but lower operating effort. Furthermore, automotive structures have smaller dimensions with more complex shapes, which makes it more challenging to avoid forming defects and to ensure complete injection. Since manufacturing makes the main difference between automotive and aerospace composite components, this feature article puts emphasis on the process technologies and on the corresponding material behavior and process simulation methods. For a holistic product design of automotive CoFRP components, a simultaneous virtual description and virtual optimization of both manufacturing process and structural capacity is necessary. Production effects must be considered in the part design and, thus, must be reliably predicted by process simulation as well as taken into account in subsequent simulation steps. This feature article therefore evaluates the current state of the art in the continuous virtual representation of CoFRP process chains, including the process steps forming, injection and curing. Furthermore, the integrated optimization along this CAE chain is a key factor for an economic part design and therefore another major subject of this article.

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“…Shojaei [15] developed a three-dimensional finiteelement/control volume method to simulate the resin flow of CRTM in thick parts. By using a finitevolume formulation, mold filling of CRTM can also be simulated for small mold gap heights, where the preform is still in contact with the tool [16]. The method enables further developments in RTM mold filling simulations, for example the implementation of resin viscosity models [17] or of advanced process variants as we present in this work.…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical investigations of pressure-controlled resin transfer molding (PC-RTM)

Seuffert

Rosenberg

Kärger

et al. 2020

Advanced Manufacturing: Polymer & Composites Science

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To increase the use of fiber reinforced lightweight structural components in the automotive industry, their manufacturing processes have to obtain demanding economic requirements. One possibility is to use Compression Resin Transfer Molding (CRTM), which is fast and can be highly automated. One disadvantage can be the very high cavity pressure during injection. To avoid this disadvantage, a pressure-controlled RTM (PC-RTM) process was developed. PC-RTM uses a variable mold gap height and an embedded pressure sensor to control the cavity pressure actively during mold filling. In this work, we investigate this process by experiments and simulations with varying initial mold gap and controlled cavity pressure. We show that PC-RTM is a viable manufacturing process with short cycle times and high robustness. Furthermore, the simulations are validated by comparison to the experiments and show the same process characteristics.

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

Cited by 12 publications

References 20 publications

Experimental and Numerical Analysis of Mold Filling in Rotational Molding

Experimental and Numerical Analysis of Mold Filling in Rotational Molding

Fast processing and continuous simulation of automotive structural composite components

Experimental and numerical investigations of pressure-controlled resin transfer molding (PC-RTM)

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