Pull Speed Influence on Fiber Compaction and Wetout in Tapered Resin Injection Pultrusion Manufacturing

2017 ◽  
Vol 25 (6) ◽  
pp. 419-434 ◽  
Author(s):  
N.B. Masuram ◽  
J.A. Roux ◽  
A.L. Jeswani
Keyword(s):  
Fiber Reinforcement ◽  
Injection Pressure ◽  
Taper Angle ◽  
Liquid Resin ◽  
Pultrusion Process ◽  
Resin Injection ◽  
Fiber Reinforcements ◽  
Resin Injection Pultrusion ◽  
Resin Penetration ◽  
Injection Pressures

In the resin injection pultrusion process (RIP), liquid resin is injected into the tapered injection chamber through the injection slots to completely wetout continuously pulled fibers. As the resin penetrates through the fibers, the resin also pushes the fibers away from the wall towards the centerline, causing compaction of the fiber reinforcements. The fibers are squeezed together due to compaction, making resin penetration more difficult; thus at low resin injection pressures, the resin cannot effectively penetrate through the fibers to achieve complete wetout. However, if the resin injection pressure is too high, the fibers are squeezed together to such an extent that even greater injection pressure is necessary to wetout the compacted fibers. The design of the injection chamber significantly affects the minimum injection pressure required to wetout the fiber reinforcements. A tapered injection chamber is considered such that wetout occurs at lower injection pressures due to the taper angle of the injection chamber. In this study, the effect of fiber pull speed on the fiber reinforcement compaction and complete fiber wetout for a tapered injection chamber is investigated.

Multiple Injection Port Simulation for Resin Injection Pultrusion

2005 ◽  
Vol 13 (6) ◽  
pp. 559-570 ◽  
Author(s):  
S.S. Rahatekar ◽  
J.A. Roux ◽  
E. Lackey ◽  
J.G. Vaughan
Keyword(s):  
Continuous Process ◽  
Injection Pressure ◽  
Processing Parameters ◽  
High Viscosity ◽  
Fibre Volume ◽  
Multiple Injection ◽  
Injection Port ◽  
Resin Injection ◽  
Resin Injection Pultrusion ◽  
Injection Pressures

Resin injection pultrusion is a continuous process for manufacturing composite materials. Complete wet-out of the reinforcement fibres in the resin injection chamber is essential for producing good quality pultruded parts. The magnitude of the injection pressure is extremely important to achieve good wet-out of the reinforcement fibres. At high pull speeds, high viscosity, or high fibre volume fractions, the injection pressures required to achieve complete wet-out are very high and are practically very difficult to achieve. This work focuses on reducing the injection pressure needed to achieve complete wet-out by using a multiple injection port system for epoxy/glass rovings and polyester/glass rovings composites. The recommended injection pressures for complete wet-out are predicted for a variety of processing parameters. Darcy's law for flow through porous media is employed for modelling the fibre/resin system of injection pultrusion. The governing equations are solved via the finite volume method to predict the resin pressure field, the resin velocity field, and the location and shape of the resin flow front. Different permeability models1,2 are used to determine the transverse permeability and the longitudinal permeability.

Using Computer Simulation as a Process Design Tool for Resin Injection Pultrusion (RIP)

2000 ◽  
Author(s):  
Zhongman Ding ◽  
Shoujie Li ◽  
L. James Lee ◽  
Herbert Engelen
Keyword(s):  
Modeling And Simulation ◽  
Process Design ◽  
Resin Transfer Molding ◽  
Transfer Molding ◽  
Pultrusion Process ◽  
Rtm Process ◽  
Resin Impregnation ◽  
Heating Section ◽  
Resin Injection ◽  
Resin Injection Pultrusion

Abstract Resin Injection Pultrusion (RIP) is a new composite manufacturing process, which combines the advantages of the conventional pultrusion process and the Resin Transfer Molding (RTM) process. It is sometimes referred to the Continuous Resin Transfer Molding (C-RTM) process. The RIP process differs from the conventional pultrusion process in that the resin is injected into an injection-die (instead of being placed in an open bath) in order to eliminate the emission of volatile organic compounds (styrene) (VOC) during processing. Based on the modeling and simulation of resin/fiber “pultrudability”, resin flow, and heat transfer and curing, a computer aided engineering tool has been developed for the purpose of process design. In this study, the fiber stack permeability and compressibility are measured and modeled, and the resin impregnation pattern and pressure distribution inside the fiber stack are obtained using numerical simulation. Conversion profiles in die heating section of the pultrusion die can also be obtained using the simulation tool. The correlation between the degree-of-cure profiles and the occurrence of blisters in the pultruded composite parts is discussed. Pulling force modeling and analysis are carried out to identify the effect on composite quality due to interface friction between the die surface and the moving resin/fiber mixture. Experimental data are used to verify the modeling and simulation results.

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

2006 ◽  
Vol 129 (1) ◽  
pp. 143-156 ◽  
Author(s):  
A. L. Jeswani ◽  
J. A. Roux
Keyword(s):  
Process Parameters ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Fiber Reinforcement ◽  
Resin Flow ◽  
Molding Process ◽  
Fiber Volume ◽  
Liquid Resin ◽  
Pultrusion Process ◽  
The Impact

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.

Impact of Processing Parameters and Tapering of Injection Chamber Walls in Resin Injection Pultrusion

2007 ◽  
Vol 15 (7) ◽  
pp. 507-519 ◽  
Author(s):  
A.L. Jeswani ◽  
J.A. Roux
Keyword(s):  
Volume Fraction ◽  
Fibre Volume Fraction ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Fibre Volume ◽  
Fibre Reinforcement ◽  
Resin Injection ◽  
Resin Injection Pultrusion ◽  
The Impact

This study seeks to improve the wet-out and thus the quality of the pultruded part in the tapered injection pultrusion process. Complete wet-out of the dry fibre reinforcement by the liquid resin depends strongly on the processing parameters. Process parameters modelled were: fibre pull speed, fibre volume fraction and resin viscosity. In this work a 3-D finite volume technique was developed to simulate the flow of polyester resin through the glass rovings. The results show the impact of the tapering of the injection chamber walls on the minimum injection pressure necessary to achieve complete fibre matrix wet-out and the resin pressure at the injection chamber exit. Important chamber design information is presented.

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

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
A. L. Jeswani ◽  
J. A. Roux
Keyword(s):  
Fiber Volume Fraction ◽  
High Pressures ◽  
Volume Fraction ◽  
Injection Pressure ◽  
Fiber Volume ◽  
High Fiber ◽  
Volume Fractions ◽  
Resin Injection ◽  
Resin Injection Pultrusion ◽  
The Impact

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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