Numerical Study of Thin-Walled Polymer Composite Part Quality When Manufactured Using Vacuum Infusion with Various...

Area of Science:

• Materials Science
• Polymer Engineering
• Manufacturing Processes

Background:

• Vacuum infusion molding is crucial for producing thin-walled polymer-composite structures.
• Optimizing process parameters is essential for achieving desired material properties and structural integrity.
• Complex geometries and material behaviors necessitate advanced modeling techniques.

Purpose of the Study:

• To model and analyze various vacuum infusion molding modes for thin-walled polymer composites.
• To investigate the influence of different process parameters on resin flow and preform consolidation.
• To identify optimal strategies for controlling vacuum infusion molding to enhance product quality.

Main Methods:

• Development of a simplified process model accounting for resin rheology and preform compressibility.
• Simulation of four distinct vacuum infusion molding modes with controlled boundary conditions and injection gate states.
• Comparative analysis of simulation results focusing on fiber volume fraction, wall thickness, and resin filling.

Main Results:

• Identification of key parameters influencing resin distribution and preform filling.
• Determination of the most effective process modes for achieving uniform fiber volume fraction and wall thickness.
• Demonstration of the simulation tool's capability in optimizing molding strategies for complex structures.

Conclusions:

• The developed simulation tool enables effective selection of vacuum infusion molding strategies.
• Optimized process control leads to improved quality of thin-walled polymer-composite structures.
• The study provides insights into mitigating defects and achieving superior composite manufacturing outcomes.