Systematic approach for the development of an FE-based process simulation framework for wet compression moulding of continuously reinforced composites

Wet compression moulding (WCM) provides large-scale production potential for continuously fibre reinforced structural components as a promising alternative to resin transfer moulding (RTM). Lower cycle times are enabled by parallelisation of the key process steps draping, infiltration and curing during moulding, which is called viscous draping. Experimental and theoretical investigations prove strong mutual dependencies between the physical mechanisms, especially between the resin (fluid) and the stacked laminate [1-4]. To enable a time and cost efficient product and process development throughout all design stages, accurate process simulation tools are desirable. Hitherto, a lack of systematic investigation and understanding of these mutual dependencies prevent further development of suitable numerical methods. Existing sequential draping and mould filling simulations models that are suitable for the RTM process cannot be directly applied to the WCM process, due to the above outlined physical couplings [5]. Numerical approaches published within the field of liquid composite moulding (LCM) [6] or vacuum assisted processes [7] already contain fluid-structure-interaction approaches. ... mehrHowever, they cannot be applied either, since they cannot account for desired forming behaviour (large deformations, large contact area and boundary condition), which is necessary for WCM process.