Reactive moulding process modelling: structural analysis of thermoset insulated electrical components

In this paper, the principles of the developed structural analysis approach for reactive moulding processes are rationalised and described. So far in the industry, the prediction of reactive moulding process induced problems that are directly related to the structural integrity of a finished product have largely been disregarded in the simulations. With the addition of the structural analysis method for reactive moulding processes, the fully three-dimensional simulation approach has been extended to cover all the process stages from mould filling, curing and post-casting heat treatment to final cooling down. The relevant physical phenomena, such as thermal and chemical deformations, that are affecting the structural integrity of analysed castings are taken into account. The utilisation of the structural analysis approach to a medium voltage industrial application case along with selected results is presented later in the paper. The combined effects of numerous variables contributing to the casting process formulate the biggest challenge for reliable analysis results.