RTM Simulations and Experiments For Fiber-reinforced Turbine Blades Forming

摘要

The one-shot (full part) forming of tidal turbine blades by RTM (Resin Transfer Molding) process is a complex process due to the complexity of reinforcements and geometry of blades. In this work, beside the experimental tests which have been realized using IRT JV high capacity machines, the RTM simulations using Moldex3D RTM software have been carried out. First of all, simulations have been done on a l/7~(th) scale part in order to determine the best injection strategy. Different tested strategies vary by the disposition of injection points (Inlet)/vacuum points (Outlet). Then, the chosen strategy has been applied on the full scale part (~7m length) of high thickness with more complex reinforcement draping. In both cases, the stage of meshing is important to take into account the draping plan with different fiber orientation and fiber types. Attention should be paid on the neck of the blade as the structure of reinforcement changes. A sensitivity study of different parameters (permeability, pressure, temperature) has been then done to understand their influence on the injection time. The permeability which lies to the choice of reinforcement type and fiber volume fraction plays an important role. As the thickness of the part is high, an experimental campaign for measuring the 3D permeability is required. Among the process controllable parameters, the pressure seems the fastest way to reduce the injection time. However, increasing the injection pressure (or the vacuum) could deform the reinforcement. Moreover, the maximal pressure depends on the machine capacity. The influence of temperature shows the thermo-dependence of resin viscosity, the injection time thus decreases as the temperature increases. Nevertheless, the gel time is more limited for injection stage if the resin is heated too much.