Simulation of resin-impregnation, heat-transfer and cure in a resin-injection pultrusion process

Sandberg, Michael; Rasmussen, Frank Engel; Hattel, Jesper Henri; Spangenberg, Jon

doi:10.1063/1.5112527

Cited by 10 publications

(8 citation statements)

References 18 publications

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“…In this context, in which the behaviors are interconnected and influence each other as described in Fig. 13b, modeling and predicting the pultrusion process performances play a key role [392][393][394][395][396]. The process parameters, namely the platen heating temperatures and the pulling speed, must be carefully ruled and optimized to mitigate the temperature peaks and avoid excessively fast reactions [391,[397][398][399][400].…”

Section: Pultrusionmentioning

confidence: 99%

Advances in composite forming through 25 years of ESAFORM

et al. 2022

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The increase in the number of structural applications of composite materials, especially in the aerospace and automotive industries, has led to a demand for robust models to simulate composite forming processes. The mechanical behaviour of composite materials during forming is relatively complex due to their fibre-matrix composition. Many research studies have been conducted in the past 25-plus years into experimental methods for the characterization of the mechanical behaviours that are exhibited by textile-reinforced composite material systems during forming and into the development of material models to be used in computer codes for forming simulations. These studies have been presented and discussed in the ESA-FORM conferences since 1997 and especially in the 'Composite Forming Processes' mini-symposium launched in 2001. This article presents a survey of the research carried out in this context. Mechanical characterization tests specific to composite forming are presented as well as recent analysis techniques such as digital image correlation and X-ray tomography. Threedimensional mechanical behaviour laws, in particular hypo-and hyperelastic, have been developed and extended to second gradient models. Specific shell approaches have been presented and their application to wrinkling analysis. Resin flow and permeability analysis is another area of research in composite forming processes which are discussed in this article. Research on certain processes is also presented, in particular thermoforming of thermoplastic composites, wet compression moulding, pultrusion, automated fibre placement and three-dimensional printing. This comprehensive review of the works of multiple research groups is a recognition of the breadth and depth of efforts that have been invested into the understanding of the manufacturability of textile-reinforced composite materials.

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Section: Pultrusionmentioning

confidence: 99%

Advances in composite forming through 25 years of ESAFORM

et al. 2022

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“…By designing a layup of appropriate fibre architectures, engineers can time the impregnation step to a suitable process window. In pultrusion, which belongs to the family of LCM processes, a layup can consist of rovings of fibres [1][2][3][4] . Here, instead of controlling the local permeability by selecting special types of fabrics or mats, permeability can be altered by applying texturisation to rovings.…”

Section: Introductionmentioning

confidence: 99%

“…In pultrusion, which belongs to the family of LCM processes, a layup can consist of rovings of fibres. [1][2][3][4] Here, instead of controlling the local permeability by selecting special types of fabrics or mats, permeability can be altered by applying texturisation to rovings. Air-texturised rovings can also be combined with matrix-forming filaments to form a commingled yarn, braided into technical fabrics, or directly enter the fibre layup in other continuous composite manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Permeability and compaction behaviour of air-texturised glass fibre rovings: A characterisation study

Sandberg

Kabachi

Volk

et al. 2020

Journal of Composite Materials

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Air-texturisation is a process that adds bulkiness to bundles of fibres. In this study, the permeability and compaction behaviour of air-texturised glass fibre rovings are experimentally characterised and compared to conventional unidirectional rovings. Based on radial impregnation experiments and single-step compaction/decompaction tests, the following main findings are highlighted: Compared to conventional unidirectional-rovings, the normalised permeability of the air-texturised rovings was approximately three times higher along the fibre direction and 40 times higher transverse to the fibre direction. Accordingly, the degree of anisotropy was approximately one magnitude lower. At a compaction pressure of 1 and 5 bar, the air-texturised rovings were compacted to a volume fraction of [Formula: see text] and 0.43, respectively, which was approximately 30% lower than the volume fraction achieved for the conventional unidirectional-rovings. Finally, it was observed that the decompaction of air-texturised rovings exhibits a more distinct elastic response when unloaded.

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“…We are not aware of any systematic experimental variation of the central influencing variables on pultruded profiles with closed impregnation. This is also referred to by Bezerra [ 35 ] as something that is urgently needed: “[…] an extensive characterization study on pultruded profiles produced under different dies and processing conditions [is necessary].” Similarly, Sandberg et al [ 36 ] also describe the current state of research in pultrusion technology: “[…] the implications and sensitivities of different process parameters are often unknown […]”. Sumarak, as well as Wu [ 37 ], summarily describe the pultrusion die as a “[…] chemical reactor that maintains a set of steady-state conditions under which the raw materials are transformed into a finished product.” [ 38 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental and Simulative Analysis of the Pressure Development in a Closed Injection Pultrusion Process with Multiple Chamber Geometries

et al. 2023

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The use of innovative higher-performance highly reactive resin systems requires an enhancement of the established method of fiber impregnation (open bath) towards closed resin-injection pultrusion (CIP), due to the short pot life of the resin systems. The result is that the open bath is developed into a closed injection and impregnation chamber (“ii-chamber”). In this study, three parameters—resin viscosity, opening angle and opening factor at the injection point on the ii-chamber—are varied, each in three stages. For each set of parameters, a pultrusion trial is conducted and the process pressures in the ii-chamber and pultrusion die measured. This enables direct feedback via the process conditions of the as yet uncured composite. The data obtained are used to validate a newly developed simulation model. The model is based on Darcy’s law, which has been extended to take fiber movement into account and thus represent the resulting pressure increase in the die. The flexible ii-chamber and die concept enhance our understanding of the processes taking place in the die system. The sensitivity of the process pressures can be shown for the three influencing variables. The experiment shows that of the three influencing variables investigated, viscosity has the greatest sensitivity to pressure development. In general, it can be said that over the length of the pultrusion die system, the pressure level increases across the three measuring points.

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Simulation of resin-impregnation, heat-transfer and cure in a resin-injection pultrusion process

Cited by 10 publications

References 18 publications

Advances in composite forming through 25 years of ESAFORM

Advances in composite forming through 25 years of ESAFORM

Permeability and compaction behaviour of air-texturised glass fibre rovings: A characterisation study

Experimental and Simulative Analysis of the Pressure Development in a Closed Injection Pultrusion Process with Multiple Chamber Geometries

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