Development of An Advanced Analysis Tool for Characterization, Simulation and Remedy of Molding Induced Defects in Liquid Composite Molding

液体复合成型工艺，如树脂传递成型（RTM）和结构反应注射成型（SRIM）是航空航天和汽车工业中发展最快的新制造技术之一。它们已被许多研究人员和工程师认为是批量生产轻质、高强度和低成本结构部件的最可行方法。在当今的航空航天工业中，用于轻质部件的主要制造技术是预浸液/高压釜工艺。这个过程是昂贵的，缓慢的和劳动密集型的。在民用航空运输业等以成本为导向的行业中，它不能很好地竞争。这就是为什么许多公司，特别是在欧洲，正在开发RTM流程的原因。在今天的汽车工业中，轻量化部件的主要制造技术是热塑性注塑成型和SMC压缩成型。这些工艺只能处理小体积的短纤维增强，因此，它们不能生产结构应用所需的高强度产品。另一方面，SRIM和RTM是基于高体积分数的连续纤维增强。它们有可能生产出比钢铁制造的零件更坚固的零件。新的流动分析实验技术包括不同纤维结构增强织物的毛细力和纤维润湿量的测量以及三维微观流动可视化和图像分析。固化分析的实验技术包括基质树脂的流变学和动力学分析以及反应性膨胀法。电脑模拟将在两个层面进行；一个足够简单的模型可以与现有的计算机代码相结合，以便快速轻松地介绍到制造部门，一个复杂的模型可以解决从模具填充到最终产品性能预测的全部问题，将利用超级计算能力进行开发。

9414287 Lee Liquid composite molding processes such as resin transfer molding (RTM) and structural reaction injection molding (SRIM) are one of the fastest growing new manufacturing technologies in aerospace and automotive industries. They have been recognized by many researchers and engineers as the most feasible approach to mass produce light weight, high strength and low cost structural components. The major manufacturing technique in today's aerospace industry for light weight components is prepreg/autoclave process. This process is expensive, slow and labor intensive. It can not compete well in the cost driven business such as the civil aero- transportation industry. This is why many companies, particularly in Europe, are developing RTM processes. The major manufacturing techniques in today's automotive industry for light weight components are thermoplastic injection molding and SMC compression molding. These processes can only handle low volume short fiber reinforcement, therefore, they can not produce high strength products which are needed for structural applications. SRIM and RTM, on the other hand, are based on high volume fractions of continuous fiber reinforcement. They can potentially produce parts stronger than steel made parts. The new experimental techniques for flow analysis include measurements of capillary forces and fiber wetting for fabric reinforcements with different fiber architecture and the three- dimensional microscopic flow visualization and image analysis. The experimental techniques for curing analysis include rheological and kinetic analyses and reactive dilatometry of matrix resins. Computer modelling will be carried out at two levels; a model simple enough to be combined with existing computer codes for quick and easy introduction to the manufacturing sector and a sophisticated model addressing the full range of mold filling to final product property prediction will be developing using supercomputing capabilit ies.