Development of a numerical code that simulates combined heat transfer, resin flow and compaction during composites processing

The cure and consolidation of thermoset composite materials is a complex physical process involving combined heat transfer, resin curing, fibre bed compaction and fluid flow. Finite difference simulations for either the heat transfer part of this process or for the resin flow part can be found in the literature. The present paper develops and implements the finite element form of the equations governing composites processing and successfully combines resin flow and heat transfer modelling through the temperature-dependent viscosity. Specifically, this paper (i) sets up the finite element form of the Fourier heat conduction equation and the Gutowski/Davé resin flow equation through the Ritz formulation, (ii) overviews the computer implementation of these equations and (iii) presents selected output results to demonstrate the engineering value of the simulation program. An autoclave process is analysed as a test case. The results illustrate that the developed computer code (FCURE) combines existing mathematical models with the versatility of the finite element method into a simulation tool with engineering potential.