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Simulation based flow distribution network optimization for vacuum assisted resin transfer moulding process

In the vacuum assisted resin transfer moulding (VARTM) process, using a flow distribution network such as flow channels and high permeability fabrics can accelerate the resin infiltration of the fibre reinforcement during the manufacture of composite parts. The flow distribution network significantly influences the fill time and fill pattern and is essential for the process design. The current practice has been to cover the top surface of the fibre preform with the distribution media with the hope that the resin will flood the top surface immediately and penetrate through the thickness. However, this approach has some drawbacks. One is when the resin finds its way to the vent before it has penetrated the preform entirely, which results in a defective part or resin wastage. Also, if the composite structure contains ribs or inserts, this approach invariably results in dry spots. Instead of this intuitive approach, we propose a science-based approach to design the layout of the distribution network. Our approach uses flow simulation of the resin into the network and the preform and a genetic algorithm to optimize the flow distribution network. An experimental case study of a co-cured rib structure is conducted to demonstrate the design procedure and validate the optimized flow distribution network design. Good agreement between the flow simulations and the experimental results was observed. It was found that the proposed design algorithm effectively optimized the flow distribution network of the part considered in our case study and hence should prove to be a useful tool to extend the VARTM process to manufacture of complex structures with effective use of the distribution network layup.