ECCM15 - 15 TH EUROPEAN CONFERENCE ON COMPOSITE MATERIALS, Venice, Italy, 24-28 June 2012 1 SIMULATION OF LIQUID RESIN INFUSION PROCESS BY FINITE ELEMENT METHOD A. Dereims 1,2,* , R. Troian 2 , S. Drapier 2 , J-M. Bergheau 3 , P. de Luca 4 1 ESI Group, Le Récamier, 70 rue Robert, 69458 Lyon Cedex 6, France. 2 Claude Goux Laboratory (UMR CNRS 5146), Structure and Material Science Center, École Nationale des Mines de Saint-Étienne, 158 cours Fauriel, 42023 Saint-Étienne CEDEX 2. 3 Laboratory of Tribology and Systems Dynamic (UMR CNRS 5513), University of Lyon, École Nationale d’Ingénieur de Saint-Étienne, 59 rue Jean Parrot, 42023 Saint-Étienne CEDEX 2, France. 4 ESI Group, Aero Business Center - Aeroparc, 25 Rue Marcel Issartier, BP 20005, 33700 Mérignac, France. *arnaud.dereims@esi-group.com Keywords: Infusion, Post-filling, Stokes, Darcy Abstract Infusion processes are a cheaper alternative to the usual injection process to realize big composite parts. However the bad control of the final properties of the molded part is a disincentive to their democratization at industrial level. We are presenting an advanced modeling method, coupling fluid flows with finite deformation solid mechanics, in order to anticipate as best as possible thickness variation of the part and infusion time. 1 Introduction Composite manufacturing processes by resin infusion have been developed for years to bring a cheaper solution to big parts production. Those processes allow a significant cost reduction in raw materials storage and mold fabrication, a shorter infusion time and limit void formation. However, the lack of control on the final properties of the part, implying long and expensive process settings, significantly reduce the above-mentioned advantages. So we are proposing a full model so simulate the liquid resin infusion process, in order, to anticipate the potential problems numerically. 2 Liquid Resin Infusion process description Liquid Resin Infusion (LRI) is among the most used infusion process in industrial application. It consists of creating a liquid film of resin, on the top of the dry preforms, thanks to a very permeable material, the distribution medium. Then, it is the pressure differential between the vent (0 bar) and the injection line (atmospheric pressure) that provokes the infusion of the resin in the thickness direction (figure 1a). Finally, a pressure and temperature cycle is applied to the system to bring the resin in a solid state. The flexibility of the vacuum bag does not allow maintaining a constant thickness during the whole process, while its good control is mandatory in the geometrical and mechanical properties of the final part.