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Analysis of flexible injection process

Analysis of flexible injection process

Courses

Resin Transfer Molding (RTM)


RTM with flexible cover

1. Impregnation phenomena in liquid resin injection


2. Modeling of composites manufacturing by injection process
(injection phase)

Compression RTM

Closing press

Positive resin pressure

3. Practical work on PAMRTM (isothermal RTM simulation)

Upper mold closes after injection

4. Industrial test cases


5. Modeling of composites manufacturing by injection process
(curing phase)

RTM-Light (ou RTM-Lite)

Elastic upper mold

Positive resin pressure

6. Practical work on PAMRTM (non-isothermal RTM simulation)

Upper mold is a thin-shell composite

7 Modeling of CRTM and resin infusion processes


7.
8. Practical work on PAMRTM (VARI simulation)

Vacuum Assisted Resin Infusion (VARI)

Plastic upper mold

9. Capillarity, saturation and injection optimization

Resin at atmospheric pressure


Upper mold is a plastic cover
Vacuum is applied into the cavity

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Analysis of flexible injection process

26 mai 2009

Analysis of flexible injection process

Classification des procds

Isothermal injections in

Brard et al.

Compression-RTM

REEF [2005]

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Analysis of flexible injection process

The C-RTM process

Analysis of flexible injection process

Isothermal injections in RTM


Governing equations

C-RTM process cycle

j
system
y
Injection

Draping
p g of fibers

Resin under pressure

Injection system is
connected

Resin is injected at high


pressure into mold cavity
while upper mold is
closed

Resin cures (cure dwell)

Part is demolded

Flow through porous media

Darcys law

Resin and fibers mass is constant


(no mass creation)

cte

cte

Mass conservation

K P
V

div (V ) 0

div(V ) div
P 0

Fibers

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Analysis of flexible injection process

Analysis of C-RTM process


f (h) f (t )
Vf

sup
vol h

Analysis of flexible injection process

Analytical solutions in C-RTM


Constant pressure

Closing velocity

Mass conservation

26 mai 2009

h0

h(t)
Mold

Mold

+
vl

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Where :

h
h
t
26 mai 2009

Is the mold closing velocity

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Analysis of flexible injection process

Analysis of flexible injection process

Analytical solutions in C-RTM


Constant Flow Rate

Isothermal injections in
Vacuum Assisted Resin Infusion (VARI)

Voir : coulements en milieu poreux compressible.pdf


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Analysis of flexible injection process

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Analysis of flexible injection process

Analysis of VARI process


Resin
Deformable
plastic bag

R i front
Resin
f

vacuum

Fabrication dune pice


par le procd VARI

seal
Rigid mould
Impregnated reinforcement
Dry reinforcement

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Analysis of flexible injection process

Vacuum Assisted Resin Infusion (VARI)

Analysis of flexible injection process

Vacuum Assisted Resin Infusion (VARI)

Mold preparation

Foam core

Ribs w/foam core

Second fiberglass cloth

Infusion pipeline

Plastic film cover

Sealing plastic cover

Verifying vacuum

Vacuum pump and


resin trap

Resulting part

Light part!

Infusion video

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Analysis of flexible injection process

Analysis of VARI process

26 mai 2009

Analysis of flexible injection process

VARI experiment

Resin
Deformable
plastic bag

14

Resin at
atmospheric
pressure

vacuum

R i front
Resin
f

seal
Rigid mould
Impregnated reinforcement
Dry reinforcement
Resin flow

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Deformation of
plastic film
Vacuum

Vacuum

15

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Analysis of flexible injection process

Analysis of flexible injection process

VARI experiment

Linear Variable
Displacement Transducer

Analysis of VARI process

Resin flow

(LVDT)

x1

Dplacementt LVDT (mm)

x2

0.9
0.8
0.7
0.6
0.5
04
0.4
0.3
0.2
0.1
0
-0.1 0

Patm

Resin flow

Pvide

x1
LVDT 1
LVDT 2

Deformation of
plastic film

Thickness

x2
Resin flow

x1
200

400

Permeability

Vacuum

x2

600

Length

Temps (s)
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Analysis of flexible injection process

Analysis of flexible injection process

Compaction of fiber beds

Compaction of fiber beds

Compaction
pressure

1. The preform thickness h varies


with applied pressure

Terzaghis law

2. Fiber volume content Vf varies


with thickness h

3. Permeability K varies with Vf

(1 V f ) 3
Vf

is the thickness of the fibers preform

voll

i th
is
the volumetric
l
ti d
density
it off th
the fib
fibers

sup

is the superficial density of the preform

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applied
fiber

Presin

applied
Hooks law

19

fiber

applied

4. The compaction behavior of fibers is Key in VARI


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fiber applied Presin

applied

sup
Vf
vol h

K C

18

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E
20

Analysis of flexible injection process

Analysis of flexible injection process

Compaction of fiber beds

Compaction of fiber beds

MTS test machine

For dry fibers, Terzaghis law gives

As preform thickness decreases, the


fiber-to-fiber contact increases

fiber applied
Simplest form

Fibers

fiber AVf B

compactio
on pressure

Compaction pressure
44.1%
52.7%

fiber
fib

59.7%
67.7%

>Vf

Source: J. Brard (2006)

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Difficulty level

Mat

Woven

Unidir.

High compaction pressure


(A t l
(Autoclave
cure))

Low compaction pressure


(VARI)

Vf
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Analysis of flexible injection process

Analysis of flexible injection process

Compaction of fiber beds

Compaction of fiber beds

Fiber compaction models

fiber AVf

[QUI, 1990]
[KIM, 1991]
[TRE, 1991]

Gutowski et al., 1987

[WU, 1994]
[RUD 1996]
[RUD,
[LUO, 1999]
[PIL, 2001]

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The fibers have an hysteretic behavior during compaction

Relations
Vf K 1 K 2

1
H
n
B
H0

(II-2)
(II-3)

(II-4)

26 mai 2009

fiber

(II 5)
(II-5)

Fc Hm
H
o
[log (V
) C]/D
fo H
10

Compaction pressure

(II-1)

Vf V1 C c log
1
log V b log a
f

(II-6)

10

[logVfo C] / D

com
mpaction pressure

Rfrences

Toll et al.,1994
1994

22

(II-7)

23

Vf

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Analysis of flexible injection process

Analysis of flexible injection process

Compaction of fiber beds


Nb of layers : 3

A lubrication effect takes place if embedded fibers are compacted

Stress relaxation appears


during compaction

Sup. Density: 410 g/m2


Continuous glass
strand mat OCF

Compaction of fiber beds

Test machine: MTS

comp
paction pressure

(2)
(1)

(3)

3 compaction cycles

Dry

Wet

Vf
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Analysis of flexible injection process

Compaction of fiber beds

Stress relaxation during compaction has a visco-elastic behavior

Stress relaxation during compaction for fiberglass mat

applied

Sample thickness
reinforcement

Permanent
deformation
Visco-elastic
Elastic
deformation

Hold time

Thickness

Cavity thickness

Thickness

Thickness

fiber

26

Analysis of flexible injection process

Compaction of fiber beds

applied

26 mai 2009

H ld time
Hold
ti

time

time

Permanent deformation is caused by network


reorganization (fibers reorientation during compaction)
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Analysis of flexible injection process

Analysis of flexible injection process

Compaction of fiber beds


4 effects influence the fiber compaction behavior

Compaction
cycles
(1)
(2)
(3)

Compaction
speed

Analysis of VARI process

Relaxation

Vf

Histeresis

Vf

Number
of cycles

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Vf

time

Rate of
deformation

Stress relaxation
(time dependence)

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Analysis of flexible injection process

30

Analysis of flexible injection process

Governing equations of VARI process

Analysis of VARI process

The continuity equation for uncompressible resin and fibres

div v l 0
t

For the resin

Patm

Resin flow

Pvide

1 div 1 vs 0
t

For the fibres


Absolute resin velocity

vl v r v s

Thickness
General form of mass conservation for the consolidation problem

Permeability

K
div
P
r

Length
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div v s

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Analysis of flexible injection process

Analysis of flexible injection process

Governing equations of VARI process

Analysis of VARI process

Assuming deformation only


through the thickness

Plastic film

Patm
t

Resin infused
at Patm

K
div
P
r

Vacuum
pressure
Pvac

Hookes law

Terzaghis law

fiber applied Presin

appl = Patm
T
Terzaghis
hi llaw

fibres

d
d


div u s
dt
dt

fiber

fiber AVf B

or

fiber applied Presin

fibres

Pres = Patm

1 dP
K
1 d


P
E dt
E dt

Pvac < Pres < Patm


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Analysis of flexible injection process

1D pressure distribution in VARI process


Pressure distribution in a
1D VARI experiment

dh
div hK P
dt
h

Pressure transducers

95
85

Res
sin pressure (kPa)

Displacement-compaction stress
relationship

df

34

Analysis of flexible injection process

Governing equations of VARI process

VARI Flow Solution

Modified Darcys law for


Deformable porous media

f A Pext P B

1D Solution
(is not a function of time if
fibers relaxation is not
taken into account)

75
65
55

Flow front
possitions (mm)

45

240
420
460

35
25
15
0

50

100

150

200

250

300

350

400

450

500

Infusion length (mm)

Voir : coulements en milieu poreux compressible.pdf


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Analysis of flexible injection process

Analysis of flexible injection process

1D pressure distribution in VARI process

Governing equations of VARI process

100

1D pressure distribution
is a polynomial function

Re
esin pressure (kPa)

90
80

240
260
280
300
320
340
360
380
400
420
440
460

70
60
50
40
30
20
10

VARI Flow Solution

Displacement-compaction stress
relationship

Flow front
possitions (mm)

Permeability-displacement
relationship

0
0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

div hK P

df

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Analysis of flexible injection process

K C

(1 V f ) 3
2

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38

VARI experiment setup


Linear Variable
Displacement
Transducer

Resin flow

(LVDT)
Presine

Vf

Analysis of flexible injection process

Compaction behavior during VARI process


Patm

Compaction
model?

f A Pext P B

Adimensional flow front position

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dh
dt

Pvac

Bottom of the
plate (mold)

Two compaction curves are


required for VARI process
Vf
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Pressure sensors
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Analysis of flexible injection process

Analysis of flexible injection process

VARI experiment setup

VARI experiments
Thickness variation at (3) positions along the length

LVDT

Fibers
Fib
thickness
= Pr-Patm

Fibers
compaction

time
Pressure
P
sensor

Pr

h
(Vf)

Resin
pressure

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Analysis of flexible injection process

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Analysis of flexible injection process

VARI experiments

VARI experiments

Variation of resin pressure at (3) positions along the length

Relative decompression of the porous medium

= Pr Patm

1,4
,

Patm

End of infusion

1,2

LVDT1
LVDT2
LVDT3

Height (mm)

Data from
LVDT Data from
pressure
sensor

0,8
0,6
04
0,4

Beginning
of infusion

0,2
0

Pvide

10

15

20

25

30

35

40

45

50

Pressure (-KPa)
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Analysis of flexible injection process

VARI experiments

Analysis of flexible injection process

VARI experiments
Static compaction is not appropriate for VARI process

De-compaction model obtained during a VARI experiment

Low sensibility of testing instrument

Beginning
of infusion

Data from
pressure
sensor

Measured
in VARI
Measured on
MTS

Data from
LVDT
End of
infusion

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Analysis of flexible injection process

VARI experiments

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Analysis of flexible injection process

VARI experiments

An hydro-dynamic coupling is observed in the


de-compaction of fibers during VARI process

Permeability and compaction models estimated


with the 1D VARI experimental setup
W t VARI
Wet
compaction test

Measured in
VARI process

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Analysis of flexible injection process

Analysis of flexible injection process

VARI experiments

VARI experiments

Validation of the 1D VARI solution

Validation of the 1D VARI solution


1 6E-04
1.6E-04
experiment
VARI
RTM

Infuse
ed resin volume (m3)

1.4E-04
1.2E-04
1.0E-04
8.0E-05

Quadratic

6.0E-05
4.0E-05
2.0E-05
0.0E+00
0

100

200

300

400

500

600

700

Infusion time (sec)


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Analysis of flexible injection process

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Analysis of flexible injection process

Decompaction of wet porous medium


A high dispersion is observed on the first VARI compaction
This induces a high variability of the resin flow

A l i off fibers
Analysis
fib
impregnation
i
ti in
i LCM

Vacuum
m Pressure (- KPa)

60
50

Test 1
Test 2
Test 3
Test 4

40
30

To remember

20
10
0
8

10

11

12

13

Wet VARI
compaction
test
14

Vf (%)
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Analysis of flexible injection process

Analysis of flexible injection process

Governing equations of flow in LCM

Governing equations of flow in LCM

Deformation of porous
media during impregnation

RTM

C-RTM

VARI

div P 0

K
dh
div h P

dt

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RTM

No deformation

K
dh
div h P
U

dt

Key parameters

Imposed
deformation (U)

C-RTM

Free deformation

VARI

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Fiber permeability

Mold closing velocity

Compaction vs Permeability curves

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Analysis of flexible injection process

Discussion

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Prof. Edu Ruiz


edu.ruiz@polymtl.ca

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