Simulation and experimental validation of flow flooding chamber method of resin delivery in liquid composite molding

A new method of resin delivery, which we refer to as the flow flooding chamber (FFC), is investigated to improve infusion time and reduce material waste associated with the Vacuum Assisted Resin Transfer Molding (VARTM) process. The FFC method uses a rigid chamber that rests on top of the bagging material and a vacuum drawn inside the chamber stretches the bag to take the shape of the chamber above the fiber preform. Resin is then drawn into this chamber unimpeded, and once the chamber is full of resin, the release of the vacuum results in application of atmospheric pressure on top of the bag that drives the resin into the fiber preform. The distribution media and other subsequent materials for its removal are not needed in this modified VARTM process. This process is mathematically modeled using a two event model that couples them by using the output conditions from the first event to the input conditions of the second event. The model is implemented in a numerical simulation so one can track the movement of the resin into the chamber and the preform. Experiments using the FFC process are conducted in complex geometries containing inserts and the flow fronts and fill times are recorded. The results compare very well with the predictions validating the assumptions made in the model to describe the flow.