Three-dimensional flow simulation of resin transfer molding utilizing multilayered fiber preform

Impregnation of the multi-layered fiber preform with injected resin was analyzed by using the control volume finite element method for three-dimensional mold filling simulation of the resin transfer molding (RTM). Numerically predicted flow fronts were compared with experimental data to validate accuracy of the numerical results and applicability of the numerical code developed in this study. Since isothermal Newtonian flow was assumed, Darcy's law and continuity equation were used as governing equations and permeability tensors employed for each layer. Flow simulation was conducted for the two types of mold geometries, i.e., rectangular plate and hollow cylinder. It was proven by comparing numerical results with experimental data that the simulation code is accurate enough to predict the flow patterns, especially when multi-layered preforms were placed in the cylindrical mold. It was also found that the filling time was reduced by using outer gates compared with the case of inner gates. Three-dimensional numerical simulation provided useful information for mold filling and can be used to design an optimum mold and make the RTM process efficient.