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=
1
j
K [ ]VP (I)
where V
= 0 (P)
The energy equation for the resin can be written as
follows [6]:
,
r
c
pr
oT
r
ot
,
r
c
pr
V
VT
r
= Vk
r
VT
r
h
v
T
f
T
r
_ _
G
.
(Q)
where ,. c
p
. k are the density, the specic heat and the
thermal conductivity of the resin, respectively. h
v
is the
convection heat transfer coecient between the ber
and the resin, T is the temperature, and is the porosity
of the ber preform. The subscripts r and f represent
resin and ber, respectively. is the viscous dissipation
rates which comes from the heat generated by the resin
ow through the pore. G
.
is the heat generated by the
resin curing reaction and is expressed as [13]
G
.
= H k
1
k
2
o
m
1
( ) 1 o ( )
m
2
(R)
The energy equation for the ber preform can be
written as follows [6]:
1 ( ),
f
c
pf
oT
f
ot
= 1 ( )Vk
f
VT
f
h
v
T
r
T
f
_ _
(S)
Mass conservation of chemical species represents the
conversion between monomer and polymer [6]
oo
ot
V
.
Vo = m
.
(T)
Fig. 1. Resin transfer modeling process.
962 S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975
where o is the degree of cure and m
.
is the chemical
reaction rate of the resin, which can be related to the
degree of cure as [13]
m
.
= k
1
k
2
o
m
1
( ) 1 o ( )
m
2
(U)
Constitutive equations can be obtained in the forms
to be used in the CVFEM technique, if the control
volume method is applied to the governing equations
[14]. First, the mass conservation equation [Eq. (2)] is
integrated for control volume and the divergence theo-
rem is applied,
_
g..
V V
du =
_
g..
V
dS = 0 (V)
Eqs. (1) and (8) are combined to yield the following
expression:
_
g..
1
j
K [ ]VP n
dS = 0 (W)
The energy equations of resin and ber [Eqs. (3)(5)]
can be joined into a single equation [Eq. (10)] by the
assumption that the temperature of the resin and the
ber become identical as the resin impregnates the dry
ber [6].
,c
p
oT
ot
,
r
c
pr
V
VT = VkVT G
.
(IH)
where ,c
p
and k are expressed as
,c
p
= ,
r
c
pr
1 ( ),
f
c
pf
k = k
r
1 ( )k
f
(II)
Integration of the combined energy equation [Eq.
(10)] for control volume with the aid of Green's theorem
yields
o
ot
_
g..
,c
p
Tdu
_
g..
,
r
c
pr
TV
dS =
_
g..
kVT n
dS
_
g..
H k
1
k
2
o
m
1
( ) 1 o ( )
m
2
du
(IP)
Likewise, the chemical species mass conservation
[Eqs. (6) and (7)] can be expressed as
o
ot
_
g..
odu
_
g..
o
dS
=
_
g..
k
1
k
2
o
m
2
( ) 1 o ( )
m
2
du
(IQ)
The boundary conditions can be stated as follows.
At the injection gate:
P
inlet
= P
0
or u
inlet
= u
0
T
inlet
= T
0
o
inlet
= o
0
(IR)
At the mold wall:
oP
on
wll
= 0
T
mold
= T
m
(IS)
On the ow front region:
P
front
= 0
k
oT
on
front
= 1 ( ),
f
c
pf
u
n
T
f0
T
_ _
(IT)
Solutions to Eqs. (12) and (13) along with the boundary
conditions [Eqs. (14)(16)] yield the resin front location
as well as pressure, temperature and degree of cure dis-
tributions as functions of time.
4. Numerical simulation
The RTM mold lling process is a moving boundary
problem, which means that the computation domain
changes continuously with time. Therefore, those con-
ventional methods such as FEM and FDM require
mesh regeneration at every time step to describe the
change of the calculation domain. The control volume
method saves much trouble in mesh regeneration when
combined with the volume of uid (VOF) [15] which is
suggested by Tadmor and Broyer [1618]. In order to
solve the governing equations, the CVFEM was used.
Discretization of the three-dimensional domain was
done with a tetrahedron nite element (see Fig. 3). A
tetrahedron element consists of four sub-volumes divi-
ded by four control surfaces. Each control volume is
composed of sub-volumes surrounding a node. For
example, as shown in Fig. 3, the control volume i is
made up of sub-volumes of every element which sur-
rounds the node i. In the CVFEM, the net ux of mass,
momentum, energy and chemical species through the
control surfaces is conserved rigorously within the cor-
responding control volume. In this method, the whole
domain is divided into a xed grid system and a scalar
parameter f is introduced for each cell to represent the
ratio of occupied volume to the total volume. As the
ow front advances, all of the control volumes can be
classied into three categories as (see Fig. 2):
f = 1: main ow region
0 - f - 1: ow front region
f = 0: empty region
S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975 963
The ow front lies over the control volumes of which
the lled fraction is between 0 and 1. If f reaches a cer-
tain value, say 0.5, the ll time at the moment is recor-
ded as the ll time of the control volume. After the
entire mold is lled, the lling patterns of the ow front
can be obtained by interpolating the recorded ll times
of the respective control volume [19]. This method
enables us ecient advancement of the ow front which
satises the mass conservation more strictly.
In the energy equation [Eq. (10)] and the chemical
species equation [Eq. (6)], the transient terms are inclu-
ded. For time integration of these equations, an explicit
method was used [20]. The necessary condition for sta-
bility can be expressed as Eq. (17) based upon the Von
Neuman stability analysis [20].
t4
2o
x
x
2
2o
y
y
2
2o
z
z
2
z
_ _
1
(IU)
where a
i
, represents the diusion coecient, u
. v
. w
[
H
= C
1
T C
2
T - T
g
( ). H
= H
T5T
g
( ) (PQ)
where H
5.41910
5
Pa s A
1
1.248310
10
min
1
E
R
3636.45 K A
2
2.043310
11
min
1
k 26.89
E1
R
100048.4 K
E2
R
9505.58 K
m
1
0.693
m
2
1.327
T
C
100
C
C
1
0.02639
C
2
8.8466
Table 2
Properties of resin and ber mat used in RTM simulation [7]
Resin Fiber
,
r
1030 kg/m
3
,
f
2540 kg/m
3
c
pr
1900 J/kg K c
pf
835 J/kg K
k
r
0.193 W/m K k
f
0.76 W/m K
K
xx
110
9
m
2
K
yy
110
9
m
2
K
zz
110
9
m
2
Fig. 5. Three-dimensional pressure distribution along the centre line for
a cube. Comparison between the analytical solution and the numerical
results for three-dimensional steady ow. Pressure of unity is applied
on one surface while the pressure is kept zero on other surfaces.
S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975 965
V
K [ ]
j
VP
_ _
= 0 (PR)
If the permeability is isotropic and the viscosity is
constants Eq. (24) can be simplied as
V
2
P = 0 (PS)
Eq. (25) can be solved for a cube of unit size and the
solution can be found elsewhere as [23]:
P =
16
o
i=0
o
j=0
sinh 1 x ( ) sin 2i 1 ( )y [ ] sin 2j 1 ( )z [ ]
2i 1 ( ) 2j 1 ( ) sinh 1 ( )
_ _
(PT)
The exact solution was compared with the numerical
solution in Fig. 5 along the center line. Both solutions
agreed well, as shown in the gure.
In order to validate the ow front advancement
scheme, a one-dimensional advancement of the resin
front was considered. The resin was injected at one sur-
face of the cube and air was ventilated at the opposite
surface. In this case, the resin ow becomes one-dimen-
sional. The exact solution for the ow front location can
be obtained as [24]
x =
2KP
0
j
t
_
(PU)
Fig. 6. Verication of the ow front advancement scheme. One-
dimensional ow in the cartesian coordinate system.
Fig. 7. Principle of the optical ber sensor. Before the resin reaches
the sensing spot, light can be transmitted through the optical ber but
leaks as soon as the resin reaches the spot.
Fig. 8. Typical signal from the optical ber sensor. The intensity of
the infrared light decreases sharply as the resin front reaches the sen-
sing bare spots on an optical ber.
Table 3
Refractive indices of air, resin and glass for l = 632.8 nm
Material Refractive
index
Mismatch with
glass ber (%)
Air 1.000293 35.6
Water 1.3307 14.4
Polyester resin 1.5556 0.13
Glass ber (silica core) 1.55365 0
Fig. 9. Experimental setup for the three-dimensional RTM mold ll-
ing process.
966 S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975
where P
0
is the injection pressure, j is the viscosity, K is the
permeability, x is the location of the owfront and t is time.
In Fig. 6, the exact solution was compared with the numer-
ical result. As can be seen, the agreement is very close.
6. Experiments
In order to further verify the numerical results, experi-
ments were performed. There are several experimental
techniques to nd out the resin front location during
the lling process such as ow visualization techni-
ques [2527], the dielectric method [29], and a
method using thermocouples [30]. In these techniques,
sensors are mainly installed on the mold surface. As a
consequence, resin ow only along the mold wall can be
monitored and hence these methods are inappropriate
to nd out the ow front location inside the ber pre-
form. In this study, the optical ber was used to moni-
tor the ow of the resin inside the thick ber preform
[28].
6.1. Principle of the ber-optic sensor
Optical ber consists of core and cladding. The core is
the path of light and the cladding is the mechanical
protection from outside impact. In this study, optical
bers with silica core and polymer cladding were used.
First, a very shod section of polymer cladding was
removed from the optical ber by burning or chemical
etching. The length of the bare spot is as short as 1 mm.
Three or four bare spots were made consecutively along
a single ber, each bare spot serving as a sensor. The
optical ber thus prepared was positioned inside the
ber preform. An infrared light signal was transmitted
through the optical ber from one end and the intensity
of the light signal was monitored on the other end. Before
the resin reaches the bare spots along the optical-ber
sensor, a relatively large light signal can be transmitted
through the optical ber (see Fig. 7). However, as the
resin reaches the bare spots, the light leaks through
these bare spots because the refractive indices of the
resin and the silica are close (Table 3) [31]. Therefore,
the intensity of the transmitted light signal drops sig-
nicantly and the arrival of the resin front can be
detected. A typical signal from the sensor is demon-
strated in Fig. 8.
Fig. 10. The locations of sensing planes where optical ber sensors
were installed, between stacked ber preform inside the mold. The
inlet gate was placed at the centre of the bottom surface and the posi-
tions of the sensing spots are given in Table 4.
Fig. 11. Installation of the optical ber sensors on each plane shown
in Fig. 10. The positions of the sensing spots are given in Table 4.
Table 4
The locations of the optical ber sensors embedded inside the ber preform for the measurement of the three-dimensional ow front location (see
Figs. 911)
Sensor 1 Sensor 2 Sensor 3 Sensor 4
x (mm) y (mm) x (mm) y (mm) x (mm) y (mm) x (mm) y (mm)
1st plane (z = 0.0 mm) 23.3 0.0 0.0 23.3 23.3 0.0 0.0 23.3
46.6 0.0 0.0 46.6 46.6 0.0 0.0 46.6
70.0 0.0 0.0 70.0 70.0 0.0 0.0 70.0
2nd plane (z = 10.2 mm) 0.0 0.0 0.0 0.0
23.3 0.0 0.0 23.3
46.6 0.0 0.0 46.6
3rd plane (z = 19.6 mm) 0.0 0.0 0.0 0.0
23.3 0.0 0.0 23.3
46.6 0.0 0.0 46.6
4th plane (z = 29.0 mm) 0.0 0.0
S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975 967
6.2. Three-dimensional permeability measurement
The three-dimensional permeability must be known
for the three-dimensional RTM mold-lling analysis.
The three-dimensional permeability was measured using
the optical-ber sensors described above.
First, the optical-ber sensors were embedded in the
ber preform at designated locations (see Figs. 10 and
11). The optical ber used in this experiment was a
multimode ber (CeramOptec, HWF 200/230/500T)
which can transmit the light of a wavelength between
0.4 and 2.4 mm. The cubic mold cavity was closed and
then resin was injected from the inlet gate at the center
of the bottom surface. As the permeability is aniso-
tropic, the shape of the resin front is known to be ellip-
soidal [28]. As the resin reached the sensor point, the
signal from the photo detector changed sharply and the
time to the sensing point was recorded. Once the times for
the resin front to reach the specic locations are measured,
the three-dimensional permeability can be estimated
from curve-tting to the following equation [28,29].
Fig. 12. Typical signals from the optical ber sensors. The voltage
outputs are obtained from photo-detector sensors after proper signal
conditioning.
Fig. 13. Dimensionless front locations along x, y and z direction versus the modied time. Experimental data are curve-tted to a line to yield the
permeability values [see Eq. (27)].
968 S.T. Lim, W.I. Lee / Composites Science and Technology 60 (2000) 961975
1
3
,
3
fi
1
2
,
2
fi
1
6
=
i
i = x. y. z (PV)
where ,
fi
=
r
i
r
0i
and
i
= K
i
P
0
t
jcr
2
0i
. r
i
is the resin-front loca-
tion and r
0i
is the radius of the inlet gate. P
0
is the inlet
pressure and t is the time for the resin front to reach a
specic sensor location. j is the resin viscosity and c is
the porosity of the ber preform.
The experimental setup is shown in Fig. 9. A halogen
lamp was used for the infrared light source. A photo-
transistor (Opto Electronics, ST-1KLA) was used for
the detection of the intensity of the infrared light. The
voltage signal from the photo transistor was amplied
and then recorded by a data acquisition system
(Advantech, PCL-812PG). In this study, three bare
spots per optical ber were prepared. Fig. 10 illustrates
how the optical bers were placed inside the preform.
Ten glass-ber mats were stacked between each sensing
plane. A total of 54 chopped-strand mats were laid up.
In the rst sensing plane, four optical bers were placed
in the x and y directions. Thus, there were 12 sensing
points in the rst plane. In the second and third planes,
two optical bers were installed and, in the fourth plane,
only one optical ber was used with one bare spot.
Therefore, the number of sensing points was 25 in one
experiment. The sensing point locations are shown in
Table 4 and Figs. 10 and 11.
In order to measure the pressure at the inlet gate, a
pressure transducer (Sea Systems, Model C208) was
used. The box-shape mold cavity was constructed of 30
mm thick aluminum plates. The mold was designed to
change the cavity height so that the ber-volume frac-
tion can be changed. The resin was pressurized by
compressed nitrogen and the inlet-gate pressure was
controlled by a pressure regulator.
Automobile engine oil (LG Caltex, SAE 7.5W/30,
viscosity=0.29 Pa s at 25
C. The preform
was preheated to 70
C and rose
immediately to the mold temperature 70
C after
injection, as injection was done at the thinnest part of
the cavity and the heat from the hot mold wall was
transferred well to the resin [see Figure 17(c)]. This
means that the resin viscosity was lowered and the ll-
ing time was shortened.
To check the eectiveness of this computer code fur-
ther, an automobile headlamp bezel was considered. In
this example, resin was injected at two points. As shown
in Fig. 18(b), the locations of the ``weld lines'' as well as
the air vents could be predicted using the code devel-
oped in this study. Next, the insert was replaced with a
thin hollow cavity without ber preform to allow easy
resin ow. Therefore, in place of a hole at the insert, a
thin resin membrane was formed after the molding. The
thin cavity allowed the ow resistance to be lowered,
resulting in a faster lling time compared with the case
with a hole [see Fig. 19(b)]. In the two example cases,
the inlet gate pressure was 0.7 MPa, the inlet tempera-
ture was also 25
C.
The last numerical example was molding of a
centrifugal-pump casing (Fig. 20). This complicated
geometry was discretized into 2035 nodes and 7874 ele-
ments. The resin was injected from the inlet surface
(surface gating) at 0.6 MPa. The temperature of the
resin and mold was 70