Center for Composite Materials Department of Mechanical Engineering

Have we Improved Processability for Liquid Molding with Process Modeling ?

Per

form

ance

Eas

e o

f P

roce

ssin

g

Melt Flow Oriented (Injection Molded)

Random Chopped Strands (SMC)

Discontinuous Collimated

Fibers

Continuous Fiber

System

Relative Processability

Relative Performance (Strength/Stiffness)

.

Injection & Compression Molding

Liquid Composite Molding

Center for Composite Materials Department of Mechanical Engineering

Domain of Composite Molding Processes

Center for Composite Materials Department of Mechanical Engineering

Macro flow modeling issues in Liquid Composite Molding

14775

Racetracking

Transverse FlowMacro Void Formation

Vent

Vent

Injection

Injection

Center for Composite Materials Department of Mechanical Engineering

Micro flow modeling issues in Liquid Composite Molding

14785

Unsaturated Effects

Micro Void FormationPreform Deformation &

Compaction

Vent

Vent

Injection

Injection

Center for Composite Materials Department of Mechanical Engineering

Issues and Challenges in Liquid Composite Molding

• Preforming• Complete Saturation and Voids• Injection and Vent Locations• Process Control• Reliability and Repeatability

Issues

Challenges•Three Dimensional Flow Modeling

•Saturation Physics

•Dimensional Tolerances

•Flow Control

•Distribution Media Design

•Location of Resin Injectors

•Automation

•Large and Complex parts

Center for Composite Materials Department of Mechanical Engineering

Will modeling improve preform Manufacturing and Processability ?

s1s2

BA

C

zoom

knots with b.c.’s

projection of y axisprojection of y axis

Center for Composite Materials Department of Mechanical Engineering

Can one improve yield despite uncertainties in process? Can modeling help?

Preform Nesting

Flow Channels

Resin Arrival onTool Surface

Center for Composite Materials Department of Mechanical Engineering

Can one introduce Control and Automation to address uncertainties in process and materials ?

Past

Future

Center for Composite Materials Department of Mechanical Engineering

The Road from Injection Molding to Liquid Composite Molding

Has Process Modeling been useful in Injection Molding?

Yes! NSF Center for Injection Molding made CAE an integralPart of Manufacturing

Why is the tech transfer so slow in Liquid Composite Molding (LCM)?

Is the Process more forgiving ?

Has it moved into the commercial zone from Military Arena ?

What more can be done to move it into the commercial zone ?

Are process models already advanced to the stage of deployment?

Why LCM industry is not willing to embrace the role of modeling?