Development of Manufacturing Technology for Cab Front Using Resin Transfer

ABSTRACT: The development of a new composite product through resin transfer molding (RTM) process requires the identification of an effective injection strategy and optimization of the process variables and raw material parameters of the man-ufacturing process. This article presents an effective manufacturing technology for a cab front model using RTM isothermal mold-filling simulation technique. The simu-lations performed were based on the finite element method for which a commercial RTM simulation package was utilized. A number of isothermal mold-filling simula-tions using different injection strategies and process variables were carried out. Injection strategy using constant flow or pressure was executed to find optimum locations for injection ports and air vents requiring minimum mold-fill time. The effect of process variables, such as injection pressure, and raw material parameters, such as resin viscosity and mat permeability, on the mold-filling time was also stud-ied. The simulation results show that the injection strategy of four injection points on the front face and four vents at the corners of the cab front with constant pressure of 5 atm delivers an optimum mold-fill time of 32min without dry spots. KEY WORDS: polymer matrix composites, resin transfer molding, mold-filling simulations, effective injection strategy, automobile applications