Towards more complete models and improved computer simulation tools for Liquid Composite Molding (LCM)

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The use of advanced composites represents a key issue in many industrial fields facing economic and environmental challenges. Over the last 15 years, "Liquid Composite Molding" (LCM) processes have been used successfully to produce lightweight primary structures in the aerospace and automotive sectors. LCM manufacturing consists of injecting a liquid reactive resin to impregnate a dry fibrous reinforcement contained in a mold cavity. LCM processes can produce high performance composite parts, have a strong potential of automation and offer several possibilities such as the use of 3D woven reinforcements to prevent delamination problems encountered in composite laminates. Several Canadian firms could benefit from the advantages provided by LCM processes, but the development of new products requires more advanced computer predictive tools. The research project aims to fill this gap by developing innovative and more precise numerical models to improve LCM simulation and predict the performance of parts. Three main research topics will be investigated: 1.Create geometrical multiscale models of the 3D architecture of fibrous reinforcements from observations obtained by X ray microtomography. This approach is based on parametric surface interpolation of fiber tows by dual kriging. It allows creating, with controlled accuracy and from a minimum number of data points, a multiscale representation of the fiber architecture of engineering textiles called « Digital Material Twin »(DMT). 2.Using DMT models, simulate flows in fibrous reinforcements of dual scale porosity, namely in fiber tows and through the mesopores between tows. This will make possible to study and visualize air entrapment and transport in engineering textiles. This kind of analysis is required to predict part quality in advanced composite applications (planes, electric cars and trucks, wind blades, etc.). 3.Develop a simple and innovative method to measure the "apparent permeability" of fibrous reinforcements filled through thickness with a "Distribution Medium"(DM). This approach will allow performing 2D flow simulations (instead of full 3D analysis) to fabricate large composite parts by "Liquid Resin Infusion" (LRI) with DM. A significant performance gain is expected by reducing the computational time by a factor of 1000, and even more in the case of complex sandwich composites with grooves and holes in the core such as the ones found in wind blades. Overall, several innovative numerical tools will be progressively developed to simulate key features of LCM processes. They will be implemented to study the LCM fabrication of parts of increasing complexity with the goal of providing practical tools to industry. The long-term objective is to create new applications of high performance composites using virtual manufacturing in process development and scale-up. Finally, the Highly Qualified Personal (HQP) trained under the project will provide a competitive edge to Canadian companies.