NUMERICAL MODELING OF LIQUID COMPOSITE MOLDING PROCESSES FOR LARGE-SIZE COMPOSITE PARTS

摘要

Infusion techniques for manufacturing large composite parts are gaining popularity in many fields such as aeronautics, nautical, and energy. The reasons vary with the domain of application: manufacturing large parts (aeronautics), reducing weight (nautical), and increasing wind turbine power (energy). Environmental issues and improving working conditions are also factors. A critical review of existing processes (RTM light, VARI, LRI, FASTRAC, etc.) is done. Material selection, consumables, and process parameters are the parameters that need to be controlled in order to avoid dry spots, bubble entrapment, curing during the infusion, and surface quality. The mechanical properties of the formed part also depend on manufacturing as well as these parameters. This paper shows how numerical simulation can assist in the development of the infusion process. The modeling of the infusion is different from the modeling of the well-established resin transfer molding (RTM) modeling because the fiber content varies during the injection. This modeling and the experiments conducted to gather the material data necessary for a realistic prediction of the infusion are detailed. Laboratory-scale validation as well as a full-boat-hull infusion simulation is reported.