Experimental and Numerical Investigation on Process Parameters in Vacuum Infusion Process for Composite Manufacturing

Abstract

Carbon fiber reinforcement polymer (CFRP) is widely used in space applications, the automobile industry, aerospace and sports equipment because of good specific properties over conventional metals and alloys. Composite parts are manufactured using various processes and every manufacturing process have independent process parameters. Thus, selection of process plays a vital role for composite manufacturing. In this dissertation, the vacuum infusion process (VIP) has been selected for manufacturing composite part. In VIP, a high volume fraction ratio is achieved with low cost compared to other process. The flat plates are manufactured using the VIP process from CFRP material. The stainless steel material has been selected as the mold material based on the coefficient of thermal expansion and availability. The consolidation materials are procured and used for manufacturing process. 4, 8 and 12 layers of CFRP flat plates have been manufactured using VIP. The process parameters i.e. resin pressure, volume fraction, part thickness and permeability are considered during VIP manufacturing process. The thickness of the flat plate has been measured using micrometer gauge at different location and found a thickness variation. The results of resin pressure and resin flow are compared using experimental and simulation approach. The numerical simulation is performed using ANSYS Fluent software. The volume of fluid (VOF) model has been used numerical approach for the tracking the interface between the two phase. The mechanical properties like compressive strength, inter lamina share strength, volume fraction and flexural strength of the manufactured composite plates has been found as per ASTM standard.