Modeling resin flow and preform deformation in composite manufacturing based on partially saturated porous media theory

In this contribution a generic algorithm to simulate resin infusion in composites manufacturing technologies such as Liquid Resin Infusion (LRI) and Resin Transfer Molding(RTM) is developed. The most important challenge to be addressed is the migration of free surface due to resin infiltration into the highly deformable fibrous preform. To do so, a compressible two-phase porous media formulation is put forward for the problem formulation and a staggered finite element based solution procedure is advocated for the total solution advancement. The approach automatically monitors the free surface, whereby the monitoring of the resin front migration using e.g. level set or front tracking control is completely avoided. The method is exemplified using a hat stringer geometry considering both manufacturing methods