Reference - Simulating Resin Infusion through Textile Reinforcement Materials for the Manufacture of Complex Composite Structures

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Type	Journal
Title	Simulating Resin Infusion through Textile Reinforcement Materials for the Manufacture of Complex Composite Structures
Abstract	Increasing demand for weight reduction and greater fuel efficiency continues to spur the use of composite materials in commercial aircraft structures. Subsequently, as composite aerostructures become larger and more complex, traditional autoclave manufacturing methods are becoming prohibitively expensive. This has prompted renewed interest in out-of-autoclave processing techniques in which resins are introduced into a reinforcing preform. However, the success of these resin infusion methods is highly dependent upon operator skill and experience, particularly in the development of new manufacturing strategies for complex parts. Process modeling, as a predictive computational tool, aims to address the issues of reliability and waste that result from traditional trial-and-error approaches. Basic modeling attempts, many of which are still used in industry, generally focus on simulating fluid flow through an isotropic porous reinforcement material. However, recent efforts are beginning to account for the multiscale and multidisciplinary complexity of woven materials, in simulations that can provide greater fidelity. In particular, new multi-physics process models are able to better predict the infusion behavior through textiles by considering the effect of fabric deformation on permeability and porosity properties within the reinforcing material. In addition to reviewing previous research related to process modeling and the current state of the art, this paper highlights the recent validation of a multi-physics process model against the experimental infusion of a complex double dome component. By accounting for deformation-dependent flow behavior, the multi-physics process model was able to predict realistic flow behavior, demonstrating considerable improvement over basic isotropic permeability models.
Authors	Pierce, Robert S Falzon, Brian G
Date	2017
Issue	5
Pages	596-607
Journal	Engineering
Volume	3
Websites	https://www.sciencedirect.com/science/article/pii/S2095809917307117
DOI	https://doi.org/10.1016/J.ENG.2017.04.006
ISSN	2095-8099
Keywords	Composite materials, Draping, Infusion, Numerical modeling, Textile reinforcement

Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

‘Preform’ is the term for the fibre reinforcement. This is the stage between the raw material form after it is processed into an architecture (fabric, mat, etc.) and becoming a composite.

For polymer matrix composites (PMCs), resin refers to the matrix; the continuous material phase that binds the reinforcement together, maintains shape, and transfers load. Resins are divided into two main groups: thermosets and thermoplastics.

Permeability refers to the resistance to fluid flow through a porous material.

• Resin flow through fibre
• Gas flow through prepreg

With regards to modelling & simulation, validation demonstrates the accuracy of a computational model — in the context of its intended use — to check that it represents the physics of the problem and the ‘reality of interest’ (needs are satisfied).