A 2D modeling approach for fluid propagation during FE-forming simulation of continuously reinforced composites in wet compression moulding

Wet compression moulding (WCM) provides large-scale production potential for continuously fiber reinforced components as a promising alternative to resin transfer moulding (RTM). Lower cycle times are possible due to parallelization of the process steps draping, infiltration and curing during moulding (viscous draping). Experimental and theoretical investigations indicate a strong mutual dependency between the physical mechanisms, which occur during draping and mould filling (fluid-structure-interaction). Thus, key process parameters, like fiber orientation, fiber volume fraction, cavity pressure and the amount and viscosity of the resin are physically coupled. To enable time and cost efficient product and process development throughout all design stages, accurate process simulation tools are desirable. Separated draping and mould filling simulation models, as appropriate for the sequential RTM-process, cannot be applied for the WCM process due to the above outlined physical couplings. Within this study, a two-dimensional Darcy-Propagation-Element (DPE-2D) based on a finite element formulation with additional control volumes (FE/CV) is presented, verified and applied to forming simulation of a generic geometry, as a first step towards a fluid-structure-interaction model taking into account simultaneous resin infiltration and draping. The model is implemented in the commercial FE-Solver Abaqus by means of several user subroutines considering simultaneous draping and 2D-infiltration mechanisms. Darcy's equation is solved with respect to a local fiber orientation. Furthermore, the material model can access the local fluid domain properties to update the mechanical forming material parameter, which enables further investigations on the coupled physical mechanisms.