Gate Effectiveness in Controlling Resin Advance in Liquid Composite Molding Processes

Abstract

In Liquid Composite Molding (LCM) processes, the flow pattern of the resin in the mold cavity during mold filling dictates the quality of the composite part. Disturbances such as uncertainty in the fiber preform permeability, variations in the resin viscosity, and racing of the resin along the mold walls may create unexpected and unanticipated flow patterns that could result in dry spots in the preform. Process control with sensor feedback can potentially provide the ability to make fully impregnated parts despite various disturbances by manipulating the flow front movement during resin impregnation through modification of the injection conditions at the gates. Studies have shown that under certain conditions, the flow front shape is not influenced by even large changes in the flow rate or the pressure at the injection gates. This study investigates gate effectiveness in modifying the flow front shape by analyzing the flow dynamics and conducting a parametric study in a simulation environment.