A parametric numerical study for the processing of highly reactive thermoset resins for liquid moulding applications

This study explores part geometrical deviations with manufacturing strategies for composite materials, focusing on highly reactive thermoset resins processed through Resin Transfer Moulding (RTM). A simulation framework that integrates the filling stage and stress-deformation analysis using a thermo-viscoelastic (TVE) model was developed to improve the understanding of material behaviour and its impact on part quality. The influence of key process parameters, including process temperature, nominal injection pressure, number of plies, and ply stacking sequence, was investigated for part geometrical deviations. The results show that the ply stacking sequence and the number of plies are the most significant factors affecting part geometrical deviation. In contrast, process temperature and injection pressure had only a minor effect. This work demonstrates the potential of the proposed simulation approach as a reliable tool for guiding experimental implementation and improving part quality when using highly reactive thermosets.