Simulation and optimization of infusion process for perforated foam sandwich composite
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摘要: 以穿孔泡沫夹芯复合材料为研究对象，对其真空辅助树脂灌注(VARI)工艺进行了实验研究、仿真分析和方案优选。首先，通过实验测试与数值计算分别得到穿孔夹芯结构织物与芯材孔洞的渗透率；然后，对穿孔夹芯结构灌注过程进行三维仿真模拟，并通过实尺度灌注实验验证了仿真模拟的可靠性；最后，基于验证的仿真模型进行工艺参数优选，拟合得到了灌注时间的预测模型。结果表明：数值仿真与实验值基本吻合，能较准确地模拟穿孔夹芯结构成型时的流动过程和孔隙分布；灌注时间的预测模型可用于指导实际生产；通过优化成型工艺参数可控制树脂的流动行为，达到缩短成型时间和降低构件孔隙率的目的。
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关键词:
- 穿孔夹芯结构复合材料 /
- 真空辅助树脂传递模塑 /
- 数值仿真 /
- 工艺优选 /
- 孔隙
Abstract: The numerical simulation of the vacuum assisted resin infusion (VARI) process of perforated sandwich composite was verified experimentally, and process optimization was presented thereafter. Firstly, the permeabilities of the fabric and holes of perforated core were obtained experimentally and numerically, respectively. Then, 3D simulation was carried out for the infusion process of the perforated sandwich composite structure and verified by real-scale infusion experiments. Finally, based on the simulation, the process was optimized by investigating the effects of injection position and type on the filling time and product porosity, and later a methodology was proposed to predict the filling time needed. The results show that the numerical simulation is in good agreement with the experiment. The flow patterns during the filling and the porosities of the perforated sandwich structures are in good match with experimental results. The filling time prediction method can be used for practical production instruction. The selection of proper parameters, such as injection position and type, can minimize molding time and product porosity. -
图 2 孔洞渗透率计算模型
r—Radius of porosity model; A—Equvalent cross-sectional area of porosity model; l—Length of porosity model; δ—Thickness of boundary layer
Figure 2. Calculation model of pore permeability
图 4 穿孔泡沫夹芯复合材料仿真模型
R—Radius of hole
Figure 4. Simulation model of perforated foam sandwich composite
图 7 穿孔泡沫夹芯复合材料上层和下层纤维层金相图像
Figure 7. Metallographic diagrams of top surface and bottom surface of perforated foam sandwich composite
图 8 穿孔泡沫夹芯复合材料孔隙率实验结果
Figure 8. Experimental results of porosity of perforated foam sandwich composite
图 9 34 s、78 s和260 s穿孔泡沫夹芯复合材料上表面树脂流动情况对比
Figure 9. Comparison of resin flow on top surface of perforated foam sandwich composite between simulation and experiment at 34 s, 78 s, 260 s
图 10 350 s、500 s和700 s穿孔泡沫夹芯复合材料下表面树脂流动情况对比
Figure 10. Comparison of resin flow on bottom surface of perforated foam sandwich composite between simulation and experiment at 350 s, 500 s, 700 s
图 11 穿孔泡沫夹芯复合材料上、下纤维层孔隙分布
Figure 11. Porosity distribution of top surface and bottom surface of perforated foam sandwich composite
图 12 穿孔泡沫夹芯复合材料VARI成型9种模型充模时间与最大孔隙率对比
Figure 12. Comparison of filling time and maximum porosity of 9 models of VARI for perforated foam sandwich composite
图 13 穿孔泡沫夹芯复合材料VARI成型导流网(DM)铺放模型
Figure 13. Layout model of distribution medium (DM) of VARI for perforated foam sandwich composite
图 14 不同导流网铺放位置的穿孔泡沫夹芯复合材料孔隙率分布
Figure 14. Porosity distribution of perforated foam sandwich composite with different laying positions of diversion network
图 15 穿孔泡沫夹芯复合材料灌注时间预测模型
t1, t2—Filling time; μ—Viscosity; x—Scale
Figure 15. Prediction of the filling time of perforated foam sandwich composite
表 1 材料参数测试结果
Table 1. Test results of material parameters
Resin viscosity/(Pa·s) Silicone oil viscosity/(Pa·s) Fiber volume fraction/vol% Permeability/(10–11 m2) Kx Ky Kz 0.21 0.1 49.2 3.26 3.26 0.1987 Notes: Kx, Ky—In-plane permeability; Kz—Permeability in thickness direction. 
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表 2 穿孔泡沫夹芯复合材料典型位置孔隙率结果对比
Table 2. Porosity measurement results in typical locations of perforated foam sandwich composite
Position 1 2 3 4 5 6 Porosity/% Simulation 2.31 1.63 3.56 1.45 1.66 0.90 Experiment 2.30 1.68 3.27 1.41 1.96 1.08
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表 3 穿孔泡沫夹芯复合材料真空辅助树脂灌注(VARI)工艺设计方案
Table 3. Different vacuum assisted resin infusion (VARI) process setups for perforated foam sandwich composite
Distribution medium (DM) location Injection form Short side 
Long side 
Central section 
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