Resin Transfer Molding Process Fundamentals, Numerical Computation and Experiments
Resin Transfer Molding Process Fundamentals, Numerical Computation and Experiments
Abstract Resin Transfer Molding (RTM) is one of the most widely known
composite manufacturing technique of the liquid molding family, being exten-
sively studied and used to obtain advanced composite materials comprised of fibers
embedded in a thermoset polymer matrix. The fibrous reinforcement is considered
a porous medium regarding its infiltration by the polymer resin. In this sense, this
chapter aims to briefly discuss multiphase flow and heat transfer theory in RTM
process, focusing on a multifluid model and the Control Volume/Finite Element
(CV/FE) method. Finally, computational analysis was developed on the basis of
ANSYS CFX and PAM-RTM commercial software’s for the investigation of the
fluid flow in RTM composite molding. In order to show the versatility and
performance of the commercial codes, RTM experiments were carried under
distinct injection pressure and fiber volume fraction conditions using plain-weave
F. F. Luz S. C. Amico
Federal University of Rio Grande do Sul, Porto Alegre, RS 91501-970, Brazil
e-mail: [email protected]
S. C. Amico
e-mail: [email protected]
J. Á. Souza
Federal University of Rio Grande, Rio Grande, RS 96201-900, Brazil
e-mail: [email protected]
E. S. Barbosa
Federal University of Campina Grande, Campina Grande, PB 58429-900, Brazil
e-mail: [email protected]
A. G. B. de Lima (&)
Department of Mechanical Engineering, Federal University of Campina Grande,
Campina Grande, PB 58429-900, Brazil
e-mail: [email protected]
J. M. P. Q. Delgado et al. (eds.), Numerical Analysis of Heat and Mass Transfer 121
in Porous Media, Advanced Structured Materials 27,
DOI: 10.1007/978-3-642-30532-0_5, Springer-Verlag Berlin Heidelberg 2012
122 F. F. Luz et al.
glass fiber cloth as the porous media. The transient numerical simulations provided
information about volume fraction, pressure and velocity distribution of the phases
(resin and air) inside the porous media.
1 Introduction
(v) potential for the production of relatively large (surface area *150–200 m2)
and thick (0.1–0.15 m) composite parts, containing high reinforcement content
(75–80 wt%) [19].
1.2.3 Infusion
In this process, the reinforcement is laid on the rigid mold with a layer of removable
flow-enhancement medium, used to reduce filling time, along with a peel ply to
facilitate disposal. Inlets and outlets are placed and the vacuum bag is sealed to the
mold using a sealant tape. Air is extracted from the cavity to compact the preform
between the vacuum bag and the mold and to subject the resin to a pressure differ-
ential that drives resin flow through the compacted preform. Infusion is a closed mold
resin infiltration production process that presents many similarities with RTM. The
most striking difference, however, is that the fully enclosing, two-part rigid mold
used in RTM is replaced with a one-part rigid mold sealed with a vacuum bag [20].
In RTM Light, a variant of traditional RTM, a more flexible mold material (e.g., a
composite) and an upper translucent component are used, allowing observation of
the progress of the resin during impregnation. For LCM processes utilizing flexible
molds such as RTM light, local laminate thickness evolution is governed by the
compaction characteristics of the reinforcement, and improved compaction models
are vital for enhanced filling simulations [21]. RTM light uses a peripheral vacuum
to seal the mold, whereas a low positive pressure along with partial vacuum in the
mold cavity drives resin flow inside the cavity industries [22]. RTM Light has been
widely used in automotive, aerospace, civil and sports [9].
In this process, a network of grooves or channels is used to distribute the resin, and
reduce flow resistance and filling time. The resin fills those grooves/channels first by
vacuum pressure and then infuses into the fiber preform. The Seemann Composites
Resin Infusion Molding (SCRIMP) is often used to produce large composites of
complex geometry such as boat hulls and decks [23]. Considering factors like
environmental protection, relatively inexpensive tooling and the ability to fabricate
large parts with complex geometry, the SCRIMP process may be used to replace
traditional open molding processes [24].
Now that we have discussed about composite materials and manufacturing of
these materials, the next step is to address discussions about modeling and
simulation applied to LCM process. Following a mathematical modeling to predict
fluid flow and heat transfer inside porous media with particular reference to RTM
process on an overall basis is presented.
126 F. F. Luz et al.
Non-isothermal fluid flow in porous media can be modeled on the basis of fluid
velocity, pressure and temperature into the media. For very small velocity, many
researchers have utilized the so called Darcy’s model, which will be presented and
discussed later.
In macroscopic scale, the porous model is a generalization of both, the Navier–
Stokes equations and Darcy’s law. The model retains both advection and diffusion
terms and can therefore be used for flows in which such effects are important. In
deriving the continuum equations, it is assumed that control volumes are infinitesi-
mal and that surfaces are large in relation to the interstitial spacing of the porous
medium but small relative to the scales in study. Thus, given control cells and control
surfaces are assumed to contain both solid and fluid regions. This is a concept of
continuum mechanics. This way, the particular details of the porous structure such as
dispersion, tortuosity and interfacial transfer between phases at the pore level are
neglected.
Dispersion is the transport due to hydrodynamic mixing of the interstitial fluid
at the pore scale (spreading phenomena). At this point, it is important to distin-
guish between dispersion and diffusion. Diffusion occurs due to random molecular
motion whereas dispersion is caused by fluctuations of the bulk flow. Then,
dispersion occurs when convection occurs [25]. Discussion about this topic can be
found in related works [25–29].
Tortuosity is a very important property of a porous medium. It is defined as the
ratio between the straight line distance and the curved path length between two
points [25]. Allen III et al. [27] defined this parameter as the average ratio between
the distance traveled by the fluid in the microscopic pores of the medium and the
net macroscopic distance traveled. Other definitions of tortuosity are given by
Vallabh et al. [30] and Epstein [31]. According to the former author, higher
tortuosity value indicates longer, more complicated and sinuous path, resulting in
greater resistance to fluid flow.
In this context, by assuming that the continuum approach provides the necessary
information, the general scalar advection–diffusion equation in a porous medium is
given by [32]:
oðq/UÞ
þ r ðqK UUÞ r ðCU K rUÞ ¼ /S ð1Þ
ot
where: t is the time, q is the density, U is the velocity vector, U is the potential of
transport, CU represents effective transport property and S the source term.
Resin Transfer Molding Process 127
In Eq. (1), the volume porosity, /; at a point is the ratio between the volume
0
V available to flow in an infinitesimal control cell surrounding the point, and the
physical volume, V; of the cell. Hence:
0
V ¼ /V ð2Þ
Nield and Bejan [33] and Bear [26] defined porosity as the fraction of the total
volume of the porous media that is occupied by pores. However, disconnected
pores can exist in the material, therefore the term effective porosity has been
defined as the ratio between the volume occupied by connected pores and overall
volume of the porous material.
0
In this formulation, it is assumed that the vector area available to flow, A ;
through an infinitesimal planar control surface of vector area A is given by:
0
A ¼ K:A ð3Þ
where: K is a symmetric second rank tensor called the area porosity tensor. The
inner product of a symmetric rank two tensor and a vector produces a vector.
In addition to the usual production and dissipation terms, the source term S may
contain transfer terms from the fluid to the solid parts of the porous medium.
Initial conditions
U ¼ f1 ðD; t ¼ 0Þ ð4Þ
Boundary conditions
U ¼ f2 ðSÞ ð5Þ
where S is the boundary of the domain.
• Prescribed flux (Newmann or second kind condition)
128 F. F. Luz et al.
oU
¼ f3 ðSÞ ð6Þ
on
oU
¼ f4 ðSÞ ð7Þ
os
where n and s represent the normal and tangential directional vectors to the
boundary S, respectively.
• Mixed (Robin or third kind condition)
oU
f5 ðSÞ þ f6 ðSÞU ¼ f7 ðSÞ ð8Þ
on
where f5 ðSÞ 6¼ 0 and f6 ðSÞ 6¼ 0 on the boundary S.
The choice of one or more conditions is dependent on the problem to be solved.
Solution of a partial differential equation applied to physical problems requires
physically realistic initial and boundary conditions. Fluid flow equations in porous
media comprise a complicated formulation that involves elliptic, parabolic and
hyperbolic terms. These different behaviors affect the way like the initial and
boundary conditions in the domain must be specified.
For a physical problem where fluid-fluid (liquid–gas) interface exists, the
momentum flux and hence the velocity gradient in the liquid is negligible com-
pared to that in the gas phase (because liquid viscosity is much greater than that of
the gas) [36]. In addition, in transient problems the initial condition, i.e., the values
of the variables, must be defined at the start of the process (t = 0).
The reinforcement (porous) media inside the mold is initially filled with air. Resin
is injected into the mold through one or more points (inlets) and air is forced out of
the mold through one or more outlets. In standard RTM, the use of a single resin
inlet and a single air/resin outlet is common. Resin injection through the rein-
forcement media can be mathematically described as a viscous fluid moving
through a porous medium. The problem consists of two inviscid fluids (resi-
n ? air) flowing through a porous media contained inside the mold cavity. Dif-
ferent approaches can be used to model the problem. In the present work, three
formulations will be discussed and compared:
1. Multifluid model;
2. Control Volume/Finite Element (CV/FE) based model;
3. Volume of Fluid (VOF) model.
Resin Transfer Molding Process 129
U ¼ R1 rp ð11Þ
Heat transfer into the porous media can be modeled with an equation similar to:
o
ð/qHÞ þ r ðqK UHÞ ¼ r ðke K rTÞ þ /SH ð12Þ
ot
where: H is the specific enthalpy, T is the temperature, ke is an effective thermal
conductivity and SH contains a heat source or sink to or from the porous medium.
130 F. F. Luz et al.
A heat transfer model attempts to obtain the temperature distribution within the
porous medium. It is important to understand the temperature profile during RTM
process for different reasons: (a) temperature for resin cure is elevated, (b) the
curing process is usually very exothermic, (c) resin viscosity is dependent on the
temperature thus, influencing mold filling time, and (d) depending of the nature of
the preform (e.g., vegetal fibers are very sensitive to heat), high temperature may
affect the final composite.
Momentum sources can be used to model isotropic losses in porous regions,
directional losses in porous regions, or other processes. For a better understanding,
consider the general momentum equation (Eq. 8) for a fluid domain in the form:
~
oðqUÞ ~ UÞ
þ r ðqU ~ ¼ rp þ qg þ r s þ SM ð13Þ
ot
where s represents the stress tensor, and g is the gravity acceleration vector.
The momentum source, SM ; can be represented by:
~ CQR jUj
SM ¼ CLR U ~ U~ þ Sspec ð14Þ
where: CLR is a linear resistance coefficient due to viscous losses, CQR is a qua-
dratic resistance coefficient referring to inertial losses; Sspec contains other
momentum sources (which may be directional) and U ~ is superficial velocity
(Darcy velocity). The relationship between true (interstitial) velocity and super-
ficial velocity, at any point in the porous medium, is given as follows:
~ ¼ /U
U ð15Þ
True velocity corresponds to the mean fluid velocity through the pores whereas
superficial velocity is the velocity that a fluid would exhibit if no reduction in
cross-sectional area of flow occurred due to the presence of the solid material.
Usually, the superficial velocity is expressed by the ratio between volumetric flow
rate and cross-sectional area of the porous medium. The particulate material within
the porous medium reduces the area available for fluid flow, therefore true velocity
is greater than superficial velocity.
On the basis of Eq. (11), Darcy’s law is only valid when the pore Reynolds number
is of the order of 1 [37]. When the microscopic Reynolds number is greater than that
(flow occurs at high velocity), Darcy’s equation is supplemented on the right-hand
side by a quadratic non-linear term corresponding to form drag within the medium to
correct the advection term (Forchheimer term) [25, 33, 38–40]. Other versions of the
Darcy’s equation exist; for example in Liu and Masliyah [25], Nield and Bejan [33],
Magyari et al. [38] and Hsu [40].
The following generalized form of Darcy’s law has been reported in the
literature:
l ~ q ~ ~
rp ¼ U þ KEL jUj U ð16Þ
KP 2
Resin Transfer Molding Process 131
where: l is the dynamic viscosity; KP is the permeability and KEL is the empirical
loss coefficient.
Permeability is a measure of how easily a single-phase fluid moves through a
porous medium under the influence of a dynamic pressure gradient [41]. Perme-
ability, defined by Ye et al. [42] as a measure of the resistance to fluid flow into a
porous material, can be obtained through experiments or analytical predictions and
different equations to calculate this parameter have been report. According to Hsu
[40], Nield [43], Lage [44], Chen and Hsiao [45], Vafai and Amiri [46], and Nield
and Bejan [33], permeability may be obtained as follows (Kozeny equation):
/3 dp2
KP ¼ ð17Þ
að1 /Þ2
^
KEL q
CQR ¼ ð22Þ
2/2
Considering KEL ¼ 0 and comparing Eq. (16) with Eq. (11), one can write:
l
R¼ ð23Þ
KP
when superficial velocity is used in Eq. (16), and
l
R¼ ð24Þ
/KP
when true velocity is used.
In practical terms, heat and mass transfer phenomena dominate resin impreg-
nation and curing (exothermic chemical reaction) in RTM. Therefore, the process
can be treated as non-isothermal reactive flow [48]. In Eq. (12), the source term
represents the energy generation by volume unit that occurs into the porous
material, e.g., heat release due to the curing process. Sometimes, impregnation of
resin into the porous material is comparatively fast and resin curing has not yet
started to alter the temperature of the fluid and, in such case, the RTM process may
be considered isothermal.
In this chapter, the medium is considered rigid, i.e., relative positions of solid
structure are constant and dilation or contraction within the porous material is
negligible. Besides, no sink phenomenon (absorption of liquid by the pores of the
fiber) occurs within the porous medium. More information about sink models can
be found in Parnas and Phelan [49] and Pillai [50].
The transient formulation presented here can be applied to 1D, 2D and 3D situ-
ations and also to all phases present into the preform, for example, resin and air. Thus,
there is a local thermal non-equilibrium condition between the phases. This math-
ematical treatment yields more accurate results than the homogeneous treatment
under local thermal equilibrium conditions. More discussion on local thermal
equilibrium condition can be found in previous works [25, 33, 40, 46, 51–59].
In addition, since the volumetric heating rate release due to curing is a function
of the degree to which the chemical reaction occurred, a curing model is required
for a more complete formulation and to obtain more realistic results. Discussion on
the cure kinetic model can be found in Advani and Hsiao [48].
In this formulation, the problem is simplified by only considering the resin. The
influence of the air flow is assumed negligible and is not taken into account in the
model. Another simplification regards the fact that the transient problem of
determining resin position as a function of time inside the mold is obtained by
successive solutions of a simpler steady-state problem.
Resin Transfer Molding Process 133
The resin velocity is formulated using Darcy’s Law, which can be mathematically
described as shown in Eq. (11). Typical polymeric resins used in the RTM process
show a non-Newtonian behavior. However, for the purpose of this chapter
(description of the basic formulation of the problem), a Newtonian approach is
suitable, being, in fact, largely used in the numerical investigation of RTM [60–62].
Thus, assuming a Newtonian incompressible fluid we can write:
rU ¼0 ð25Þ
Fig. 1 CV/FE solution. a Step 1 Discretization b Step 2 Pressure field calculation c Step 3 Velocity
field calculation d Step 4 Filling time calculation and e Step 5 Determination of the new flow front
Resin Transfer Molding Process 135
velocity field is parallel to the x axis, thus only the u component of the velocity
vector is presented, however depending on the problem and geometry, both u and v
components of U are calculated with Eq. (11). It is also possible for the resin to
enter the control volume by two or more faces and leave the control volume
through one or more faces when unstructured grids are used. The same analysis is
valid for 3D solutions, though all three velocities components (u, v and w) must be
considered in the formulation. In Fig. 1c, only the velocity vectors that are
entering the volumes adjacent to the flow front are shown. These velocities are
needed in the calculations, but it is possible to use Eq. (11) to calculate the flow
velocity for all volumes.
The filling time for all volumes adjacent to the flow front is calculated in the
fourth step (Fig. 1d). With the velocity field U and the volume V of each control
volume, the filling time of volume i can be calculated by
Vi Vif ðtÞ
Dti ¼ ð27Þ
V_ ðtÞ
where: Vi is the overall volume of the control volume i, Vif ðtÞ ¼ f V i ðtÞ is the filled
volume at time t (current time step), and V_ t ðtÞ ¼ Unormal A is the volumetric flow
rate into volume i. Additionally, Unormal is the velocity component in the direction
normal to the face with area A.
The advance in the flow front position can be calculated by determining the
control volume that will be the first to be completely filled with resin. This can be
done by using Eq. (27) to identify the control volume with minimum Dt: Calcu-
lation of Dtmin guarantees that at least one control volume is completely filled and
that none of them will overflow (to receive more resin than its volume) in every
solution step.
All other volumes adjacent to the flow front will be partially filled. The filling
factor of these volumes for the next time step is calculated by
The fast solution of Eq. (26) will not always represent an overall fast solution of
the problem. Depending on the discretization, it is possible that only one new
volume is completely filled in every time step. When this happens, the number of
time steps needed to solve the problem will be equal to the number of volumes in
the grid (Nv), implying that Eq. (26) will be solved Nv times. In an attempt to
increase the number of volumes completely filled in every time step, it is
recommended to use grids with elements of the same size and, if possible, aligned
with the resin flow. The use of rectangular (2D) or hexahedral (3D) elements is
also recommended.
In general, the VOF method [68] can be used to model multiphase flows with two
or more inviscid fluids. In this formulation, all phases are well defined and the
volume occupied by one phase cannot be occupied by the others. The volume
fraction concept is used to represent the existence of different phases inside each
control volume. All fractions are assumed continuous in space and time and their
sum, inside each control volume, is equal to one. If the volume fraction of a
particular phase inside a control volume is denoted as fi, then the following three
conditions are possible:
1. fi = 0: the cell is empty with fluid of phase i;
2. fi = 1: the cell is full with fluid of phase i;
3. 0 \ fi \ 1: the cell contains the interface between phase i and one or more
other phases.
For the particular case of modeling resin and air flowing through a porous
media (e.g., in RTM), only two phases are considered in the formulation. In the
VOF method, only a single set of momentum and continuity equations is applied to
both fluids, and the volume fraction of each fluid in every computational cell
(control volume) is tracked throughout the domain. The model is composed of
continuity, volume fraction and momentum equations as follows:
oq
þ r ðqUÞ ¼ 0 ð29Þ
ot
oðqf Þ
þ r ðqfU Þ ¼ 0 ð30Þ
ot
oðqU Þ
þ r ðqU Þ ¼ rp þ r s þ qg þ B ð31Þ
ot
where: f is the volume fraction of resin and s is the stress tensor.
Since a single set of equations is used for both phases, average properties for q
and l need to be defined. These properties can be approximated as [69]
Resin Transfer Molding Process 137
used for very complex geometries, there is no regularity in the arrangement of the
control-volumes (cells). Methods of grid generation can be found in related books
[71, 72]. The grid can present uniform or non-uniform size distribution. For higher
accuracy of a particular physical problem in regions where a large gradient is
expected, the non-uniform grid size distribution is more effective [36].
For liquid composite molding, flow is transient, and mold and preform may
present a very irregular shape. In this case, an adequate grid is essential to the
accuracy of the solution, mainly when we apply a three-dimensional treatment. In
addition, depending on the specific liquid molding technique and the particular
mold design and construction being investigated, the mold may display defor-
mation (change in relative position between the upper and lower parts of the mold)
during infiltration. This brings significant challenges related to grid generation
along the transient process and, because of that, researches usually consider the
mold and grid to be rigid during RTM process. In spite of the importance, just a
few works on this the research area are available [73–75].
Luz [76] and Luz et al. [77] conducted several experiments of resin injection into a
parallelepipedic porous preform (300 9 300 9 2 mm). The Newtonian fluid used
in the experiments was a commercial vegetable (soybean) oil with density of
914 kg/m3. The fluid viscosity at 23 C (same temperature of the experiments),
measured in a Brookfield viscometer HBDV-II ? C/P with the S40 spindle, was
37.1 cP. As the fibrous reinforcement, plain-weave (0/90) E-glass fiber cloth from
Owens Corning (300 g/m2) was used.
Resin Transfer Molding Process 139
Fig. 3 Radial RTM system available at UFRGS (Brazil): a pressure pot, b strengthened-glass
top mold, c steel bottom mold, d pressure controller, e pressure transducers, f data acquisition
system and g camera
Fig. 4 Geometry of the injection mold with the dimensions of the studied area of the mold
(300 9 300 9 2 mm
/l 2 rff 1
K¼ r ln r2ff r2inj ð36Þ
2Pinj tff ff rinj 2
where: rinj is the radius of the injection port, / is the porosity of the porous fibrous
media (/ = 1-Vf, Vf is the fiber volume fraction) and Pinj is the pressure (gauge)
in the resin injection gate. During infiltration, position (radius) of the flow front
was recorded with a camera at different times.
The injection pressure of the resin in the mold was monitored with pressure
transducers during each experiment. Several experiments were performed by
varying the volumetric fiber content and injection pressure. The conditions of each
experimental run, and the observed mold filling time and the calculated perme-
ability data (Eq. 36) are presented in Table 1.
In the LCM process, simulations are being used mainly to verify the trial-and-error
approach, which is still prevalent in the manufacturing industry. However, as the
composite structures being manufactured by LCM become larger and more
complex, use of process simulation may aid in improving the process design and
increase the yield by counterbalancing any unforeseen disturbances that may arise
during the impregnation phase [48].
For the application of the models and equations presented, it is necessary the
use of a software to solve them. In modeling by RTM, simulation software are
used to (i) predict the resin injection profile and then be able to evaluate the filling
time, that should remain below the resin curing time, (ii) predict impregnation
deficient (dry) points, and (iii) determine the more suitable injection and outlet
points of air/resin.
Flow simulation software may be used, increasing the confidence in the mold
design and fabrication process parts. There are different software dedicated
exclusively to study RTM process such as PAM-RTM from ESI Group, the
RTM-WORX from Polywork, the LIMS from the University of Delaware that are
Resin Transfer Molding Process 141
Fig. 5 a The grid used in the ANSYS CFX simulations, b Details of the outlet port
very commonly used by industry for having a simple usage and focused only on
this process. However, dedicated software may end up limiting some more pro-
found studies on the process behavior in adverse situations. In fact, it is possible to
use commercial software, not only dedicated to the study of composite processing,
but computational tools that allow customization of the problem being studied.
However, adapting such software to solve specific problems of RTM can be quite
laborious. The non-dedicated commercial software commonly used to study CFD
are Ansys CFX and FLUENT, both from ANSYS and Abaqus CFD from Simula
Abaqus.
Herein, RTM modeling was applied to the manufacturing of a composite with
paralellepipedic shape by considering the isothermal system, i.e., no heat transfer.
The geometry and dimensions of the mold are shown in Fig. 4. For the 3D
numerical analysis, it was used two commercial softwares: ANSYS CFX (non
RTM-dedicated) and PAM-RTM (RTM-dedicated).
In the ANSYS CFX model, the system is composed of air, resin and solid
material (glass fiber). Simulations were performed in a structured 3D mesh with
17,532 elements and 23,876 nodes. It was built using ANSYS ICEM CFD software
version 12.0.1 and time step 0.05 s. Figure 5 illustrates the mesh used in the
142 F. F. Luz et al.
simulations. From the collected pressure data, a non-linear regression was made
using the Mathematica software, yielding a pressure equation as a function of
the process time (Eq. 37):
(
P0 þ a1 t0:25 þ a2 exp a4aþa
3t
; for 0 t te
Pinj ðtÞ ¼ 5t ð37Þ
Pe ; for t [ te
In the PAM-RTM model, the system is composed of resin and solid material (glass
fiber). It was used a 2D mesh with 14,819 elements and 16,775 nodes. Figure 6
illustrates the mesh used in the simulations. PAM-RTM, unlike the ANSYS CFX,
is a commercial software dedicated to the study of RTM process, so it was not
Resin Transfer Molding Process 143
fa and fr are the volumetric fractions of air and resin, respectively; Ua and Ur velocity vector of air
and resin, respectively; P is the static pressure at the inlet and outlet boundaries of the preform;
n is the normal direction to the boundaries
necessary make adjustments and create regression equations for the pressure data.
The collected pressure data was directly implemented in the software.
In all simulations, the preform was initially considered as having pressure (Pi),
temperature (Ti), and air saturation (Sai) homogeneously distributed throughout the
mold with the following values: Pi = 1013.23 mbar, Ti = 300 K and Sai = 1.0
(consequently, resin saturation is Sri = 0.0). The adopted boundary conditions are
presented in Table 3.
The variation of the volume fraction of fluid in the experiments and simulations in
ANSYS CFX and PAM-RTM was analyzed. Figure 7 shows a comparison of the
evolution of the volume fraction of fluid in the case P09V40 obtained by exper-
iment and numerical simulation generated by the ANSYS CFX and the PAM-
RTM at three different times 60, 150 and 360 s.
It is observed that the flow front moves in radial direction in the experiments
and in the simulations the same pattern is observed, but the impregnated region is
further defined and there is a regular circle. This is because in the simulations is
considered a homogeneous distribution of fibers in the cloth, and constant prop-
erties (permeability, porosity and viscosity), which are not always the cases,
experimentally. Where there is a local variation of the concentration of fibers
generates a forward heterogeneous flow. This problem can be corrected by
including in the simulation permeability as a function of saturation resin, for
example, or yet porosity as a function of position into the preform.
144 F. F. Luz et al.
®
Experimental ANSYS CFX PAM -RTM
(a)
(b)
(c)
Fig. 7 Evolution of the fluid flow front (resin) in the case P09V40 in a 60 s, b 150 s and c 360 s
It is shown in Fig. 8 a comparison between the rff experimental, the rff predicted
by ANSYS CFX and PAM-RTM at the moment twall for the experimental cases
P07V40, P09V40 and P10V40. Table 4 presents a comparison between the twall
experimental and twall predicted in ANSYS CFX and PAM-RTM for all the
simulated cases, showing their percentage deviations compared to twall
experimental.
Comparing the twall, it is observed that there is no errors exceeding 10 %,
indicating a strong relationship between the numerical solution of the equations of
porous medium and the experimental procedure. Considering the cases P01V20,
P01V30 and P01V40 observes a relation between the error and the change in Vf,
because as Vf is increased while keeping Pinj constant, the error is increased. This
behavior is not observed in other cases, when increasing the Pinj and Vf remains
constant.
As seen in Table 1, the KP highest values are found in these same three cases,
thus the deviations of comparing the numerical simulations may be related to an
experimental errors, as in the KP determining, which is a crucial property to the
success of the numerical simulation. Therefore, the deviations indicated in Table 4
can be linked to the experimental procedure and, for example, the following
Resin Transfer Molding Process 145
®
Experimental ANSYS CFX PAM -RTM
(a)
(b)
(c)
Fig. 8 Comparison between rff experimental and rff simulated by ANSYS CFX and PAM-RTM
at the moment twall experimental for the cases a P07V40, b P09V40 and c P10V40
Table 4 Comparison between the twall experimental and twall simulated in ANSYS CFX and
PAM-RTM for all the simulated cases
Case Experimental ANSYS CFX PAM-RTM
twall (s) twall (s) Deviation (%) twall (s) Deviation (%)
P01V20 130 138 6.15 131 0.77
P01V30 420 450 7.14 430 2.38
P01V40 2280 2506 9.91 2389 4.78
P03V40 1000 1098 9.80 1031 3.10
P05V40 700 768 9.71 722 3.14
P07V40 640 700 9.38 648 1.25
P09V40 560 588 5.00 568 1.43
P10V40 380 405 6.58 378 -0.53
of the reading of PAM-RTM twall for the case P10V40 accused a value below zero,
indicating that this time was less than the experimental time, as this was the only
case where this occurred, it is evident that these errors are related to experimental
errors.
By observing the deviations shown in Table 4, it is noted that they are higher in
ANSYS CFX simulations in all cases, ranging from 5.0 to 9.91 %, while in the
PAM-RTM these deviations were in the range -0.53 and 4.78 %. In both, the
higher deviations was found in the case of higher twall, the P01V40 case, as
mentioned before, is the case with most experimental error. Moreover, since the
slightest deviation found for ANSYS CFX was in the case P09V40 and for PAM-
RTM in the P10V40 case, there is no apparent relationship of deviation and the
time of molding.
Figure 9 shows the pressure distribution along the mold in the instant twall for
the case P09V40 simulated in ANSYS CFX (Fig. 9a) and simulated with the
PAM-RTM (Fig. 9b). As expected, the maximum pressure is located in the fluid
injection port, and decreases as it moves away from this point, establishing into a
regular field of pressure. In the simulation by using ANSYS CFX, the total
pressure corresponding to the sum of Pinj plus the P0, so the high pressure value
indicated in Fig. 9a; in PAM-RTM, the pressure gauge is displayed. The pressure
field seen in a transverse plane is shown in Fig. 10 generated by the ANSYS
CFX. It is noteworthy that this level of detail can not be observed in the 2D
model of the PAM-RTM. The pressure in most part of the mold is 1.01 bar,
42.19 % less than the Pinj (1.89 bar) showing quantitatively the pressure drop over
the mold.
Comparing the images generated by ANSYS CFX and by PAM-RTM in all
images presented above, is observed a better quality in the ANSYS CFX images,
indicating a concern in smooth the variation of values in the range of colors on this
software. Therefore, analyse the results is easier because it’s possible to observe
more details in these regions, especially in the analysis of fluid volumetric fraction.
4 Concluding Remarks
Fig. 9 Total pressure field from the case P09V40 in twall simulated in a ANSYS CFX and
b PAM-RTM
Fig. 10 Total pressure field simulated in ANSYS CFX in a transversal plane shown the
injection port for the case P09V40
Acknowledgments The authors thank to the Brazilian agencies CNPq (Conselho Nacional de
Desenvolvimento Científico e Tecnológico) and CAPES (Coordenação de Aperfeiçoamento de
Pessoal de Nível Superior) for supporting this work, and are also grateful to the authors of the
references in this chapter that helped in the improvement of quality. Sincere thanks to Prof. João
M.P.Q. Delgado (Editor) by the opportunity given to present our research in this book.
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