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TECHNICAL PAPERS

Manufacturing Modeling of Three-Dimensional Resin Injection Pultrusion Process Control Parameters for Polyester/Glass Rovings Composites

[+] Author and Article Information
A. L. Jeswani

Department of Mechanical Engineering, The University of Mississippi, University, MS 38677aniljeswani@gmail.com

J. A. Roux

Department of Mechanical Engineering, The University of Mississippi, University, MS 38677

J. Manuf. Sci. Eng 129(1), 143-156 (Aug 15, 2006) (14 pages) doi:10.1115/1.2383148 History: Received October 24, 2005; Revised August 15, 2006

Pultrusion, sometimes referred to as continuous resin transfer molding process, is a continuous, cost-effective method for manufacturing composite materials with constant cross sections (such as rod stock, beams, channels, and tubing). The objective of this study is to improve the fiber reinforcement wetout and thus the quality of the pultruded part in the injection pultrusion process. The complete wetout of the dry reinforcement by the liquid resin depends on various design and process parameters. The process parameters modeled in this study are fiber pull speed, fiber volume fraction, and viscosity of the resin. In the present work, a three-dimensional finite volume technique is employed to simulate the liquid resin flow through the fiber reinforcement in the injection pultrusion process. The numerical model simulates the flow of polyester resin through the glass rovings and predicts the impact of the process parameters on wetout, resin pressure field, and resin velocity field. The location of the liquid resin flow front has been predicted for an injection slot as well as for five discrete injection ports.

Copyright © 2007 by American Society of Mechanical Engineers
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References

Figures

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Figure 10

Injection pressure as a function of fiber volume fraction for injection slot and discrete ports (U=0.0254m∕s, μ=0.75Pas, HD=0.003175m, WD=0.0635m)

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Figure 11

Steady-state flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot resin injection configuration U=0.0254m∕s, μ=0.75Pas, slot location=0.1m (not to scale). (a)Vfo=0.595 (Case 7), (b)Vfo=0.724 (Case 9).

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Figure 12

Centerline (CL) and die wall (DW) pressure (gauge) profile for different fiber volume fractions for slot injection

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Figure 13

Injection pressure (gauge) as a function of viscosity for injection slot and discrete ports (U=0.0254m∕s, Vfo=0.68, HD=0.003175m, WD=0.0635m)

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Figure 14

Centerline (CL) and die wall (DW) pressure (gauge) profiles for different resin viscosities for slot injection

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Figure 15

Steady-state flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot resin injection configuration U=0.0254m∕s, Vfo=0.68, slot location=0.1m (not to scale). (a)μ=1.00Pas (Case 10), (b)μ=0.50Pas (Case 11).

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Figure 16

Steady-state flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and discrete port injection configuration U=0.0254m∕s, Vfo=0.68, μ=0.75Pas, discrete port location=0.1m (not to scale)

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Figure 1

Schematic of resin injection pultrusion

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Figure 2

Schematic of the computational domain for slot injection chamber in xy plane (not to scale)

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Figure 3

Schematic of the computational domain for slot injection chamber in xz plane (not to scale)

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Figure 4

Schematic of the computational domain for discrete port injection chamber in xy plane (not to scale)

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Figure 5

Schematic of the computational domain for discrete port injection chamber in xz plane (not to scale)

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Figure 6

Injection pressure to achieve wetout as a function of pull speed for injection slot and discrete ports (Vfo=0.68, μ=0.75Pas, HD=0.003175m, WD=0.0635m)

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Figure 7

Flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot resin injection configuration U=0.0254m∕s, Vfo=0.68, μ=0.75Pas, slot location=0.1m (Case 5) (not to scale). (a) Simulated time=0.16sec, (b) simulated time=1.00sec, (c) simulated time=3.1sec, and (d) simulated time=9.8sec.

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Figure 8

Centerline (CL) and die wall (DW) pressure (gauge) profile for different pull speeds for slot injection

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Figure 9

Steady-state flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot resin injection configuration Vfo=0.68, μ=0.75Pas, slot location=0.1m (not to scale). (a)U=0.02032m∕s(48in.∕min) (Case 4), (b)U=0.0508m∕s(120in.∕min) (Case 6).

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