1D-3D cell coupling simulation of resin flow behavior in perforated sandwich composite materials
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摘要: 真空辅助树脂灌注工艺(VARI)作为一种高性能、低成本的制造技术，已广泛应用于大型复合材料零部件的制造。穿孔夹芯复合材料具有比强度比模量高、承载能力强等特点，然而，为了准确模拟穿孔夹芯复合材料中树脂的充模过程，需要对芯材内每个孔洞的树脂流动行为进行三维数值计算，尤其是对于大厚度构件而言需要大量的开发成本和生产周期。为了降低仿真计算复杂性和时间成本，本文提出了一种全新的3D-1D有限单元耦合计算方法，利用自开发ANSYS Fluent UDF子程序模拟树脂在芯材孔洞中的流动，避免了对数量巨大的孔洞进行物理建模，成功优化了穿孔夹芯复合材料真空灌注过程的模型构建和仿真计算过程，并通过实尺度的灌注实验验证了仿真模拟的可行性。研究结果表明，数值仿真与实验测得的灌注时间基本吻合，能够较为准确地模拟穿孔夹芯结构成型过程中树脂的流动。
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关键词:
- 真空辅助树脂灌注工艺 /
- 夹芯复合材料 /
- 芯材孔洞 /
- 单元耦合 /
- 流动仿真
Abstract: The Vacuum Assisted Resin Infusion process (VARI), recognized as a high-performance, cost-effective manufacturing technology, has been widely adopted in the production of large composite material components. Perforated core composite materials exhibit characteristics such as a high strength-to-weight ratio and strong load-bearing capacity. However, to accurately simulate the resin infusion process within perforated core composite materials, three-dimensional numerical calculations of resin flow within each hole of the core material are required, especially for thick components, involving substantial development costs and production cycles. To reduce the complexity and time costs of simulation calculations, this study proposed a novel 3D-1D finite element coupling method. Utilizing a self-developed ANSYS Fluent User-Defined Function (UDF) subroutine to simulate resin flow within the core material holes, the need for physical modeling of a large number of holes is avoided. This approach successfully optimizes the model construction and simulation calculation process of the vacuum infusion process for perforated core composite materials. The feasibility of the simulation was validated through full-scale infusion experiments. The research results indicate that the numerical simulation closely aligns with experimentally measured infusion time, providing a relatively accurate representation of resin flow during the formation process of perforated core structures. -
图 10 穿孔泡沫夹芯复合材料树脂流动前沿位置对比
Figure 10. Comparison of resin flow front position of perforated foam sandwich composite
图 11 40 s、201 s和702 s穿孔泡沫夹芯复合材料上表面树脂流动情况对比
Figure 11. Comparison of resin flow on top surface of perforated foam sandwich composite between simulation and experiment at 40 s, 201 s, 702 s
图 12 460 s、620 s和970 s穿孔泡沫夹芯复合材料下表面树脂流动情况对比
Figure 12. Comparison of resin flow on bottom surface of perforated foam sandwich composite between simulation and experiment at 460 s, 620 s, 970 s
表 1 材料参数测试结果
Table 1. Test results of material parameters
Material Symbol Value Inlet pressure/Pa $ {P}_{\mathrm{i}\mathrm{n}} $ 0 Outlet pressure/Pa $ {P}_{\mathrm{o}\mathrm{u}\mathrm{t}} $ −101325 Resin viscosity/Pa·s $ {\mu }_{\mathrm{r}} $ 0.25 Resin density/(kg·m−3) $ {\rho }_{\mathrm{r}} $ 1100 Silicone oil viscosity/MPa·s $ {\mu }_{\mathrm{s}} $ 78.4 Silicone oil density/(kg·m−3) $ {\rho }_{\mathrm{s}} $ 963 Fiber volume fraction/vol% $ {V}_{\mathrm{f}} $ 41.1 Permeability/(10−11m2) $ {\mathit{K}}_{\mathit{x}} $ 3.41 $ {\mathit{K}}_{\mathit{y}} $ 3.77 $ {\mathit{K}}_{\mathit{z}} $ 0.2908 Notes: Kx, Ky−In-plan permeability; $ {\mathit{K}}_{{\textit{z}}} $− Permeability in thickness direction. 
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表 2 不同单元尺寸网格划分方案
Table 2. Meshing scheme of different element sizes
Scheme Upper and lower fiber
panels size/mmCore
size/mmElement/104 a 0.1 0.1 97.2143 b 0.25 0.1 62.4066 c 0.5 0.25 46.4243 d 1 0.5 23.4103 e 1 1 7.8904
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