Lattice Boltzmann method for the simulation of multiphase flows through fibrous porous media arising in Resin Transfer Molding

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New materials known as composites are widely used in manufacturing sectors today, among them the marine, automotive and aerospace industries. Modern aircraft contain a number of components built with these man-made materials, and it is highly important to make these components lighter, while maintaining and even improving their mechanical strength. In this context, our project concerns the industrial moulding of composite materials (CM) in a process called Resin Transfer Moulding (RTM). Essentially, this process consists of fitting a reinforcement material (woven fabric) impregnated with a resin solution inside a mould cavity. Once the resin has solidified, the particular shape given by the mould (a boat hull, for example) is obtained, producing a high quality part. Current RTM processes produce a certain amount of air entrapment (porosity), which harms the mechanical properties of CM. Consequently, porosity reduction in RTM is a primary industrial goal. However, the main factors causing this problem are not yet fully understood. In this respect, our work in this project is aimed at developing a computerized alternative to experimentally prototyping the mould-filling process, that is, a computer program for performing virtual RTM. This methodology has the advantage of being less costly and less time-consuming than the one currently used, and will enable engineers to simulate as many processes as needed, with different resin injection points and flow rates, and various types of fabrics, until a piece with enhanced mechanical properties is obtained. The success of this project will be guaranteed by our expertise and know-how in flow modelling and on comparisons with experimental data available from the work of RTM experts.