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Research Papers

Impact of Fiber Volume Fraction and Resin Viscosity With Die-Detached Tapered Chamber in Resin Injection Pultrusion

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

Department of Mechanical Engineering, University of Mississippi, University, MS 38677jeswani_anil@yahoo.com

J. A. Roux

Department of Mechanical Engineering, University of Mississippi, University, MS 38677meroux@olemiss.edu

J. Manuf. Sci. Eng 132(2), 021007 (Mar 31, 2010) (11 pages) doi:10.1115/1.4001138 History: Received May 08, 2009; Revised January 22, 2010; Published March 31, 2010; Online March 31, 2010

Complete wetout of the dry fiber reinforcement by the liquid resin depends strongly on the fiber volume fraction and the resin viscosity of the part being manufactured by rein injection pultrusion. High fiber volume fractions and high resin viscosity values yield high pressures in the tapered resin injection chamber; this work investigates the use of a an injection chamber detached from the pultrusion die in order to lower the resin pressures inside the injection chamber caused by the injection chamber tapering. A 3D finite volume technique was developed to simulate the flow of resin through the glass rovings for a variety of resin viscosities and fiber volume fractions. The results illustrate the impact of the tapering of the injection chamber walls on the minimum injection pressure necessary to achieve complete fiber matrix wetout and the resin pressure induced inside the tapered injection chamber. The results provide important injection chamber design information.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Detached die configuration

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Figure 2

Schematic of the computational domain for the slot injection chamber configuration (not-to-scale)

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Figure 3

Injection pressure as a function of fiber volume fraction for an injection slot configuration with detached injection chamber (U=0.0254 m/s, μ=0.75 Pa s, HD=0.003175 m, and WD=0.0635 m)

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Figure 4

CL and chamber wall (DW) axial pressure (gauge) profiles for CR=1.2 at different fiber volume fractions for the slot injection configuration with detached injection chamber

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Figure 5

CL and chamber wall (DW) axial pressure (gauge) profiles for CR=1.5 at different fiber volume fractions for the slot injection configuration with detached injection chamber

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Figure 6

CL and chamber wall (DW) axial pressure (gauge) profiles for CR=2.0 at different fiber volume fractions for the slot injection configuration with detached Injection chamber

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Figure 7

Flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot injection configuration with detached injection chamber, CR=1.2, U=0.0254 m/s, Vfo=0.595, and μ=0.75 Pa s; slot location is 0.10 m (case 2, not-to-scale)

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Figure 8

Flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot injection configuration with detached injection chamber, CR=1.2, U=0.0254 m/s, Vfo=0.64, and μ=0.75 Pa s; slot location is 0.10 m (case 3, not-to-scale)

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Figure 9

Flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot injection configuration with detached injection chamber, CR=1.2, U=0.0254 m/s, Vfo=0.724, and μ=0.75 Pa s; slot location is 0.10 m (case 4, not-to-scale)

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Figure 10

Injection pressure as a function of resin viscosity for an injection slot configuration with detached injection chamber (U=0.0254 m/s, Vfo=0.68, HD=0.003175 m, and WD=0.0635 m)

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Figure 11

CL and chamber wall (DW) axial pressure (gauge) profiles for CR=1.2 at different resin viscosities for the slot injection configuration with detached injection chamber

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Figure 12

CL and chamber wall (DW) axial pressure (gauge) profiles for CR=1.5 at different resin viscosities for the slot injection configuration with detached injection chamber

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Figure 13

Flow front profile and gauge Isopressure (kPa) contours for polyester resin/glass roving and slot injection configuration with detached injection chamber, CR=1.2, U=0.0254 m/s, Vfo=0.68, and μ=0.5 Pa s; slot location is 0.1 m (case 5, not-to-scale)

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Figure 14

Flow front profile and gauge isopressure (kPa) contours for polyester resin/glass roving and slot injection configuration with detached injection chamber, CR=1.2, U=0.0254 m/s, Vfo=0.68, and μ=1.00 Pa s; slot location is 0.1 m (case 6, not-to-scale)

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