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Contents
Title Page i
Dedication ii
Approval of the Viva-Voce Board iii
Certificate by the Supervisors iv
Declaration v Acknowledgement vi
List of Figures vii
List of Tables x
List of Symbols and Abbreviations xii
Abstract xiii
Contents xiv
Chapter 1 Introduction 1-11
1.1 Polymer Matrix Composites 1
1.2 Processing Methods 3
1.3 Moulding Techniques 6
1.3.1 Hand Lay Up Process 6
1.3.2 Resin Transfer Moulding Process 7 1.3.3 Resin Transfer Moulding vs. Hand Lay Up 8
1.4 Scope and Objectives 8
1.5 Work Plan 10
Chapter 2 Resin Characterization 12-52
2.1 Materials 13
2.2 Resin Gel Time and Exotherm Behaviour 14
2.2.1 Introduction 14
2.2.2 Experimental Method 16
2.2.3 Empirical Gel Time and Exotherm Model 17
2.2.4 Results and Discussions 17
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2.2.4.1Effect of Volume Ratios of Catalyst and Accelerator on Resin Gel Time and Exotherms
17 2.2.4.2 Effect of Accelerator and MEKP Volume Ratio on Gel Time 18 2.2.4.3 Effect of Accelerator and MEKP Volume Ratio on Peak
Exotherm Time 20
2.2.4.4 Effect of Accelerator and MEKP Volume Ratio on Peak
Exotherm Temperature 22
2.2.4.5 Effect of Accelerator and MEKP Volume Ratio on Rate of
Rise in Temperature 24
2.2.4.6 Effect of Accelerator and MEKP Volume Ratio on Volume
Shrinkage 26
2.3 Resin Cure Kinetics 28
2.3.1 Introduction 28
2.3.2 Experimental Method 31
2.3.3 Cure Kinetics Modelling 31
2.3.4 Results and Discussions 33
2.4 Resin Rheokinetics 40
2.4.1 Introduction 40
2.4.2 Experimental Method 43
2.4.3 Modelling of Resin Rheokinetics 44
2.4.4 Results and Discussions 45
2.4.4.1 Isothermal Viscosity Experiments 45 2.4.4.2 Determination of Degree of Cure at Different Isothermal
Temperatures 47
2.4.4.3 Super Imposed Degree of Cure vs. Viscosity vs. Cure Time
Curves 48
2.4.4.4 Viscosity as a Function of Degree of Cure and Temperature 49
2.5 Conclusion 51
Chapter 3 Reinforcement Characterization 53-81
3.1 Introduction 53
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3.2 Reinforcements 58
3.3 Porosity 59
3.4 Permeability 59
3.4.1 Permeability based on Flow Tracking using Test Fluid Electrical
Conductivity 60
3.4.1.1 Experimental Set-Up 60
3.4.1.1.1 Test Fluid Delivery System 61
3.4.1.1.2 Mould 62
3.4.1.1.3 Flow Sensor 62
3.4.1.1.4 Pressure Transducer and Data Acquisition System 62
3.4.1.1.5 Test Fluids 64
3.4.1.2 Results and Discussions 65
3.4.2 Permeability based on Flow Tracking using Visualization Technique 68
3.4.2.1 Methodology 68
3.4.2.2 Isothermal Mould Filling Experiments 70 3.4.2.3 Isothermal Mould Filling Simulations 70
3.4.2.4 Permeability Validation 70
3.4.2.5 Results and Discussions 71
3.4.2.5.1 90° Woven Roven Mat Permeability 71
3.4.2.5.1.1 Sensitivity Analysis 71
3.4.2.4.1.2 Permeability Validation 73
3.4.2.5.2 Chopped Strand Mat Permeability 75
3.4.2.5.2.1 Sensitivity Analysis 75
3.4.2.5.2.2 Permeability Validation 78
3.4.2.5.3 Comparison between 90° Woven Roven Mat and
Chopped Strand Mat 80
3.5 Conclusion 81
Chapter 4 Development of Resin Transfer Moulding Technology for
Composite High Speed Train Cab Front 82-115
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4.1 Introduction 82
4.2 Literature Review 82
4.2.1 Numerical Methods 83
4.2.3 Mould Filling Simulations 85
4.2.4 Gate and Vent Optimization 86
4.2.5 Air Entrapment Simulation 87
4.2.6 Curing Simulation 89
4.2.7 Resin Transfer Moulding Process Simulation Packages 89
4.3 Process Model 90
4.3.1 Component Selection & Discretization 90
4.3.2 Resin Flow Model 91
4.3.3 Air Entrapment Model 93
4.3.4 Resin Cure Model 93
4.4 Results and Discussions 94
4.4.1 Injection Strategy 94
4.4.2 Effective Process Parameters 104
4.4.2.1 Effect of Injection Pressure on Mould Fill Time 104 4.4.2.2 Effect of Resin Viscosity on Mould Fill Time 105 4.4.2.3 Effect of Mat Permeability on Mould Fill Time 106
4.4.3 Master Process Simulation 107
4.4.4 Air Entrapment Simulations 109
4.4.5 Resin Curing Simulations 111
4.5 Conclusion 115
Chapter 5 Scaling Down Methodology for a Composite Prototype 116-121
5.1 Introduction 116
5.2 Scaling Down Strategy 117
5.2.1 Scaling Down Criteria 117
5.2.2 Analytical Prediction 117
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5.3 Result and Discussions 119
5.4 Conclusion 121
Chapter 6 Experimental Validation 122-134
6.1 Introduction 122
6.2 Mould Filling Simulations 124
6.3 Mould Filling Experiments 127
6.3.1Experimental Set Up 127
6.3.1.1 Scaled Down Mould 127
6.3.1.2 Resin Injection System 129
6.3.1.3 Flow Visualization System 130
6.3.2 Materials 131
6.3.3 Experimental Method 131
6.3.4 Results and Discussions 131
6.4 Conclusion 133
Chapter 7 Summary 135-140
Contributions of the Thesis 141
Future Directions of the Thesis 142
References 143
Curriculum Vitae 157
List of Publications 159
