Numerical simulation of liquid composite molding processes
Keywords:
LCM processes, THM coupling, convection-diffusion, saturation, porous mediumAbstract
This work proposes to perform an analysis about the numerical simulation of LCM processes. After a description of the modelling context of these processes, our first part will describe the formulation of the laws, and a second step the application with the Thermo- Hydro-Mechanical coupling. We present a finite element procedure to simulate mold filling in the three dimensional case. The method presented in the paper is div-conform i.e. the mass of injected fluid is proved to be perfectly conserved. Numerical results are compared with experiments. In order to take into account the micro-macro voids during the filling of the reinforcement, we introduce a phenomenon of transport in saturation corresponding to a mechanism of hydrodynamic dispersion. This study is supplemented by a study of coupling between processes and mechanical properties, insisting on the advantage of introducing the concept of saturation.
Downloads
References
Acheson J.A., Simacek P., Advani S.G., “The implication of fiber compaction and saturation
on fully coupled VARTM simulation”, Composites Part A, Vol. 35, 2003, pp. 159-169.
Achim V., Ruiz E., Soukane S., Trochu F., “Optimization of flow rate in Resin Transfert
Molding”, Proceedings of the 8th Japan International SAMPE, Tokyo, Japon, 2003.
Bailleul J-L., Sobotka V., Delaunay D., Jarny Y., “Inverse algorithm for optimal processing
of composite materials”, Composites Part A, Vol. 34, 2003, pp. 695-708.
Bear J., “Continuum Approach and Contaminant Transport in Ground Water Flows”,
Modelling and Applications of Transport Phenomena in Porous Media, Von Karman
Institute for Fluid Dynamics, Lecture Series 1990-01, 1990.
Bickerton S., Abdullah M.Z., “Modeling and evaluation of the filling stage of the
injection/compression molding”, Composites Science and Technology, Vol. 63, 2003,
pp. 1359-1375.
Binetruy C., Calcul et validation expérimentale de la perméabilité et prévision de
l’imprégnation de tissus en moulage RTM, Thèse de Doctorat, Ecole des Mines de Douai,
Blest D.C, McKee S., Zulkifle A.K., Marshall P., “Curing simulation by autoclave resin
infusion”, Composites Science and Technology, Vol. 59, 1999, pp. 2297-2313.
Bréard J., Henzel Y., Trochu F., Gauvin R., “Analysis of dynamic flows through porous
media. Part I: Comparison between saturated and unsaturated flows in fibrous
reinforcements”, Polymer Composites, Vol. 24, No. 3, 2003a, pp. 391-408.
Bréard J., Saouab A., Bouquet G., “Numerical simulation of void formation in LCM”,
Composites Part A, Vol. 34, 2003b, pp. 517-523.
Bréard J., Saouab A., Bouquet G., “Dependence of the reinforcement anisotropy on a three
dimensional resin flow observed by X-Ray radioscopy”, Journal of Reinforced Plastics
and Composites, Vol. 18, No. 9, 1999, pp. 814-826.
Bréard J., Modélisation de la perméabilité/compressibilité des renforts fibreux et contrôle de
la santé matière lors de la mise en forme des matériaux composites. Application à la
simulation des procédés LCM “Liquid Composite Molding”, Habilitation à diriger des
Recherches, Université du Havre, 2004.
Bruschke M.V., Advani S.G., “A numerical approach to model non-isothermal viscous flow
through fibrous media with free surfaces”, International Journal for Numerical Methods
in Fluids, Vol. 19, 1994, pp. 575-603.
Cadinot S., Aspects rhéologiques de la compressibilité d’un renfort fibreux pour matériaux
composites : études en compression et relaxation, Thèse de doctorat, Université du Havre,
Chen B., Cheng AHD., Chou TW., “A non-linear compaction model for fibrous performs”,
Composites Part A, Vol. 32, No. 5, 2001, pp. 701-707.
Coussy O., Mécanique des Milieux Poreux, Éditions Technip, 1991.
Farina A., Preziosi L., “Non-isothermal injection molding with resin cure and preform
deformability”, Composites Part A, Vol. 31, 2000, pp. 1355-1372.
Fournier R., Optimisation du procédé RTM, Thèse de doctorat, CEMEF-Ecole des Mines de
Paris, 2003.
Gao D.M., Trochu F., Gauvin R., “Numerical analysis of the Resin Transfer Molding process
by the finite element method”, Advances in Polymer Technology, Vol. 12, No. 4, 1993,
pp. 329-342.
Hill R., Muzumar S., Lee L., “Analysis of volumetric changes of unsaturated polyester resin
during curing”, Polymer Eng. And Sci., Vol. 35, No. 10, 1995, pp. 852-859.
Kang M.K., Lee W.L., “A flow front refinement technique for the numerical simulation of the
Resin Transfert Molding process”, Composites Science and Technology, Vol. 59, 1999,
pp. 1663-1674.
Kang M.K., Lee W.L., “Analysis of vacuum bag Resin Transfer Molding process”,
Composites Part A, Vol. 32, 2001, pp. 1553-1560.
Labat L., Bréard J., Pillut-Lesavre S., Bouquet G., “Void fraction prevision en LCM parts”,
European Physical Journal- Applied Physics , Vol. 16, No. 2, 2001, pp. 269-279.
Lacoste E., Mantaux O., Danis M., “Numerical simulation of metal matrix composites and
polymer matrix composites processing by infiltration : a review”, Composites Part A,
Vol. 33, 2002, pp. 1605-1614.
Le Riche R., Saouab A., Bréard J., “Coupled RTCM and composite layup optimization”,
Composites Science and Technology, Vol. 63, 2003, pp. 2277-2287.
Lomov S.V., Huysmans G., Luo Y., Parnas R.S., Prodromou A., Verpoest I., Phelan F.R.,
“Textiles composites : modelling strategies”, Composites Part A, Vol. 32, 2001,
pp. 1379-1394.
Loos A.C., MacRae J.D., “A process simulation model for the manufacturing of a bladestiffened
panel by the resin film infusion process”, Composites Science and Technology,
Vol. 56, 1996, pp. 273-288.
Maier R., Rohaly T., Advani S., Fickie K., “A fast numerical method for isothermal Resin
Transfert Molding filling”, Int. Journal for Numerical Methods in Eng., Vol. 39, 1996,
pp. 1405-1417.
Ngo N.D., Tamma K.K., “Non isothermal 2D flow/3D thermal developments encompassing
process modelling of composites: flow/thermal/cure formulations and validations”,
International Journal for Numerical Methods in Engineering, Vol. 50, 2001, pp. 1559-
Park J., Kang M.K., “A numerical simulation of the resin film infusion”, Composite
Structures, Vol. 60, 2003, pp. 431-437.
Patel N., Lee LJ., “Modeling of void formation and removal in liquid composite molding.
Part II: model development and implementation”, Polymer Composites, Vol. 17, No. 1,
, pp. 96-103.
Pham X.T, F. Trochu, “Simulation of compression resin transfer molding to manufacture thin
composite shells”, Polymer Composites, Vol. 20, No. 3, 1999, pp. 436-459.
Pitchumani R., Ramakrishanan B., “A fractal geometry model for evaluating permeabilities of
porous preforms used in LCM”, Int. J. of Heat and Mass Transfer, Vol. 42, 1999,
pp. 2219-2232.
Ryan M.E., Dutta A., “Kinetics of epoxy cure: a rapid technique for kinetic parameter
estimation”, Polymer, Vol. 20, 1979, pp. 203-206.
Remacle J-F., Bréard J., Trochu F., “Numerical analysis of the Liquid Composite Molding by
LCMFLOT”, Proceedings of the 5th Conference on Flow Process in Composite
Materials, Plymouth, Angleterre, 1999.
Remacle J-F., Bréard J., Trochu F., “A natural way to simulate flow driven injections in
Liquid Composite Molding”, Proceedings of the 6th International Conference on
Computer Methods in Composite Materials, Montréal, Canada, 1998, In Computer
Methods in Composite Materials VI, pp. 97-107.
Ruiz E., De la caractérisation des matériaux et simulation du procédé à l’optimisation de la
fabrication des composites par injection sur renfort, PhD, Ecole Polytechnique de
Montréal, 2004.
Saouab A., Bréard J., Bouquet G., “Contribution to the optimization of RTM and CRTM
processes”, Proceedings of the 5th International ESAFORM, Krakow, Pologne, 2002a.
Saouab A., Le Riche R., Bréard J., “Couplage procédé propriétés: analyse d’une plaque
composite”, Revue des Composites et Matériaux Avancés, Vol. 12, No. 3, 2002b, pp. 515-
Sevostianov I.B., VerijenkoV.E., von Klemperer C.J., “Mathematical model of cavitation
during resin film infusion process”, Composite Structures, Vol. 48, 2000, pp. 197-203.
Spaid M., Phelan F., “Modeling void formation dynamics in fibrous porous media with the
Lattice Boltzmann method”, Composites Part A, Vol. 29, No. 7, 1998, pp. 749-755.
Torres Carot R., Boust F., Poitou A., “The concept of permeability in the Resin Transfert
Molding process: Darcy’s law and multiple porosity”, Publications de l’ONERA, 2001.
Tucker C., “Heat Transfer and reaction issues in Liquid Composite Molding”, Polymer
Composites, Vol. 7, No. 1, 1996, pp. 60-72.