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A composite roll over bar for a coach is to be made from a thick glass fibre / epoxy resin laminate with a PVC foam core. The application of Liquid Composites Moulding technology allows the integrated production of the composite / sandwich part. In order to optimise the production in terms of robustness and cost-effectiveness, process simulation techniques have been applied for the manufacture of a demonstrator part. The simulations of resin flow and temperature distribution inside the mould are compared to resin injection experiments and the results of temperature measurements. While the simulation techniques are found to reproduce experimental results qualitatively well, they are still of limited predictive value for the manufacture of geometrically complex thick parts.

Investigation of the influence of local inhomogeneities in the textile permeability on the resin flow in liquid composites moulding processes