Design of effective injection strategy and operable cure window for an aircraft wing flap composite part using neat resin characterization and multi‐physics process simulation

Abstract A methodology using neat resin characterization and multi‐physics process simulation was proposed to develop a resin transfer molding (RTM) process for an aircraft wing flap composite part. Initially, RTM6 resin was thermally characterized using differential scanning calorimetry and curing kinetics was modeled using Kamal and Sourour model. A multi‐physics approach was employed to simulate the RTM mold filling and curing phases. Mold filling simulations were performed to obtain an effective injection strategy for the composite part. One‐point injection port and five‐point vents were obtained as an effective injection strategy using a trial and improvement process. Curing simulations were performed on the composite part using neat resin cure kinetics and cure process windows for neat resin and composite panel were developed. Subsequently, a cure difference window was developed to investigate cure difference progression between neat resin and composite panel at the processing conditions. Finally, the kinetics of cure difference progression was modeled as a function of neat resin cure conversion to design operable cure cycles for the composite panel. The results found that the cure differences converge with the increase in applied mold temperature.