Simulation of the injection process in resin transfer molding

A simulation based on Darcy's law for modeling mold filling in resin transfer molding has been developed. The simulation uses a new Flow Analysis Network (FAN) technique to predict and track the movement of the free‐surface, and a finite element method to solve the governing equation set for each successive flow front location. A variety of element types have been incorporated into the simulation, enabling modeling of flow for a variety of conditions of industrial interest including runner distribution systems, “2.5‐D” shell geometries, and fully 3‐D flows. The FAN technique developed here has two main benefits: it enables conservation of mass, even for highly distorted element shapes, and also, allows elements of different dimension to be simultaneously used in a single simulation. At present, the simulation predicts flow front position as a function of time, and the pressure distribution during the filling process for a number of inlet gating conditions. A number of examples are presented and discussed to highlight the simulation's capabilities, including the filling of a complex automotive part.