NSF Workshop on Polymer Processing,June 9-10, 2004.ppt

NSF Workshop on Polymer Processing,June 9-10, 2004 Hari Dharan University of California at Berkeley Present researchResin Transfer Molding New concept for resin transfer molding (RTM) in which tool articulation provides significantly faster mold fill time compared to conventional RTM processes. Outline Review of conventional RTM Darcy’s Law and its components Current analytical methods based on Darcy’s Law Example of one-dimensional analysis for mold fill time Drawbacks with conventional RTM Factors affecting permeability Tool articulation concepts Resin “peristalsis” by tool articulation One-dimensional analysis for mold fill time using articulated tool Advantages and drawbacks Some suggestions for future investigations Introduction In RTM, the mold is packed with a dry fiber preform in which the fibers are oriented in the desired directions for reinforcing the part. The preform is impregnated by resin injected through one or more ports in the mold. After the mold is filled, the resin solidifies by cross-linking and the part is removed from the mold. There are currently many analyses and computer programs that simulate the mold filling process. Prior Work Gonzalez, Castro and Macosko (1985): axisymmetric analysis 1-D (analytical and numerical) Coulter and Gü?eri (1988): 2-D finite-difference code for isothermal flow Young, et al (1991): included variable permeability effects Bruschke and Advani (1993): non-isothermal flow using finite-element method Others: Hieber and Shen (1980), Trochu and Gauvin (1992): numerical simulation issues Issues to be addressed Modeling of conventional processes should predict defects and flow paths. Adjustments in conventional processes should be applied to eliminate predicted defects, increase process speed, widen range of allowable parameters (viscosity, molecular weight, temperature, reaction times). Transfer to industry via interactive programs (instrumented prototype machinery, correlation with models, validate improved