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    Resin_Flow_simulation_based_on_advanced composites structures

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    Resin_Flow_simulation_based_on_advanced composites structures

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    7 views8 pages

    Resin Flow Simulation Based On Advanced

    Uploaded by

    Spiridon Koutsonas
    Resin_Flow_simulation_based_on_advanced composites structures

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 8
    RESIN FLOW SIMULATION BASED ON ADVANCED REINFORCEMENT GEOMETRY MODELLING FROM YARN-SCALE TO COMPONENT-SCALE, ‘Andreas Endruweit, Frank Gommer, Jee! Hutchinson, Spirdon Koutsonas, Andrew C. Long, Peter Schubel, Xueliag Xiao, Xuesen Zeng Faculty of Engncoring~ Division of Materials, Mechanics & Structures, University of Notingham, University Park, Nottingham, NG7 2RD, UK Corresponding author's e-nall andreas endrnsei@nottngham ac uk ABSTRACT: The architectures of ttle reinforcements were characterised experimentally ‘at diferent length scales, The obained data allowed geometrieal models to be generate, for ‘whieh impregnating resin flow was simulated. Transverse yar permeabilities for random lament arrangements, modelled base on typieal nearest neighbour dstebutions, ar log- sormally distributed and significantly smaller than permeabilities for wniform yams. Flow ‘elocty feds indicate probabilities fr intra-yarn dry spt formation. Detaled modeling of ‘low channel geometries in unit cells of fabrics with complex architectures allowed in and though-thckness permeabilities tobe obtained, which are in good quantitative agreement ‘with experimental data, For nonsniforn fabrics characterised by distributions of fre angles, ‘peal mould filling patterns were predicted. Global permeabilities were determined, which ‘showed variability in the same order atypical experimental results. Analysis of gap between the reinforcement and the surface of 1 moulding tool at bends in the component geometry “ndiatedracetracking a the outer rads ofthe bend and lagging ofthe Now front atthe inner ads, as observed experimentally. Relist simulation of the impregnation of preforms with ‘dynamically varying thickness in processes with flexible tooling was enabled by combination ‘of flow and compression modeling KEYWORDS: Liguid Composite Moulding, resin flow, merical analysis, permeabiliy, textile modelling INTRODUCTION Jn Liquid Composite Moulding (LCM) processes, the impregnation of textile reinforcement with liquid resin is affected bythe eenforcement propetes at diferent length seales. Effects OF, eg capillary pressure (jam-scal), defined fibre shear (unt celUcomponent-scale) and Uniform compaction (componentscale) have been discussed extensively in the iterate ‘Additional subjets of study are related wo process-induced reinforcement non-uniformity and Sochastie properties, which ean influence the outcomes of resin injections atthe eomponent- scale. This overview summarises recent developments and curent activities atthe University ‘of Notingham in modelling reinforcement properties at different scales and ther influence on resin flow in LCM processes 5B YARN-SCALE ‘The formation of interilament voids during impregnation, which can affect (matte dominated) mechanical properties of a composite, is related to random filament distributions in yams and the resulting non-uniform resin flow velociy feds. Based on microscopic snalysis of moulded and eured composite specimens, local distributions of filaments in yarns ‘were characterised statistically a different flee volume factions. The distributions were described by the typical distance berween a filament and its nshe nearest neighbour (Fg. 1. ‘This allows instances of filament arangemens epresentative ofthe actual random bundles to be reconsructed. Fig. [: Typical stances, dh, between any filament and it mth nearest neighbours at different ‘ibe volume fractions (forthe example of a uniiectional earbon fe fabric) ene peat et, ons Aw Fig 2: A: simulated transverse flow velocity field fortwo different instances of random filament arangements a V = 0.63; B: calculated tansvese permeability asa function of Y 5K RCEEDINGS CT eM IANA, ALEKLAND Hee Using the commercial Computational "uid Dynamics (CFD) package Fluent™, steady-state transverse flow through these random filament arrangements was simlated numerically “Transverse permeabilities, derived from the applied pressure gradients and the eaeulated flow velocity fields (Fig. 2A), are log-normally distributed at any given fibre volume fraction. AS ‘the average permeabilities decrease wih Sneeasng fibre volume Faction, their seater tends to decrease due toa reduction of the filent mobility. The fat that the permeability tends to be signifcaily smaller than the permeability for ideal uniform filament arrangements (Fg 2B) according to Gebart [1 indicates clearly the limitations of numerical permeability preditions based on small periodic anit ces and the need to account for the satseal ‘Sistribution of Filaments within yen, Maps ofthe flow velocity fields (Fig 2) indent that the majority af fil nue thigh = limited number of intrfilament channels. Zones of low flow velocity in steady-state saturated flow are relted to high loa ilament density and indicate high probability for void formation in impregnating transient flow. Thus, evaluation ofthe flow veloc distibution can help to estimate the probable vod content. UNIT CELL-SCALE For 3D weaves as examples for reinforcement fabrics with geometrically complex auchitcetres, detailed geometry data were acguited by x-ray micro-Computed Tomography (CT) scanning of composite specimens (Fig. 3A). These data were converted to accurate unit tell geometry model (Fig, 3B) using the TexGen software [2], The unit ell domains were ‘meshed with uniform hexahedral voxels. Steady-state low through pore spaces was simulated using the commercial CFD package Ansys CFX™ (Fig. 30) Fig 3: 3D onhogonal carbon fibre wemves A: slice from micro-CT 3D dataset (low channels ‘in warp diretion appear Black) De TeaGzn model of unt ell geomety:C: streamlines fromm (CED simulation of flow in warp-dtetion For the example of «3D orthogonal woave, he eesults suggest that flow is dominated by the Binder yar arangement. On the surfaces of the weave, dimples form at crossover points of the binder with weft yams due to Toeaised compeetion, Confeming the suggestions from an ‘experimental study (3, they connect toform Mow channels on the fabri surfaces (Fig. 3C). In ‘he layers of aligned Yarns in the fabs, the binder blocks aps beoveen warp yams while sis PROOEEDNGS OFTHE FCM CONFERENCE ALCAN S12 JUL 20 ‘open gaps remain inthe weft direction. From the applied pesture gradients along diferent fabric directions andthe calculated low velocities, inplane and. thoughthickness rermeshilfies ween determined. In agreement with experimental observations 2, the n- plane permeability in the warp direction was found tobe significantly lower than inthe weft Airection. Accurate modelling of variations in yarm cross-sections allowed good quantiative agreement with experimental data tobe obtained COMPONENT-SCALE “Transient impregnating flow in porous media can be deseibed by combining Darcy's lw and the equation of continuity, which are implemented in several simulation codes. In this study, the commercial code PAM-RTM™ is ured for resin flow simulation athe component-sale ‘To predict typieal mould filling pattems and estimate ranges for global permeability values, fabric non-uniformity related to yarn inplane waviness was taken into account in flow simulations. Continuous random fields describing the yarn spacing forthe example of bi Aiectionalnon-rimp fabrics (Fig. 4) were generated based on trigonometric functions with the random parameters frequency and phase, Maximum values of te random frequencies (in non-ctimp fibres determined mainly bythe stitching patern) ae deermined fom fibre angle variations observed in actual fabrics (Fi. 48). From the functions describing the yarn spacing, continuous distributions of the local fibre volume fraction are calculated. Permeability fields are estimated based on local homogensition and the Kozeny-Carman uation (5) B wt Fig 4: Example of 445° non-

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