Mold Filling Simulation of Sandwich Composite Structures Manufactured by Liquid Molding: A Parametric Study

The mold filling stage in the manufacturing of sandwich composite structures with fiber reinforced foam core was studied with numerical simulations. Three different geometries of sandwich core reinforcement were considered in the form of fiber layers forming angles of 450 or 900 with the facings or in the form of equally spaced separate strands (webs). The influence of variable core and face reinforcement permeability and location of the injecting edge on the flow front progression and filling time was explored. The results suggest that permeability of the core has a significant influence on filling pattern and mold filling time. Experimental and predicted flow front developments and flow rates for a radial injection case under constant pressure were compared.