Reducing loss of resin flowing in porous fibrous media in simulation of composites fabrication

Although, the conventional finite element nodal control volume (FE/NCV) simulation procedure for resin flow through porous fibrous media is very versatile, easy, and requires no remeshing, it does lead to the loss of flowing resin mass within a porous domain. The reasons behind such mass loss are identified and systematically analyzed. Limitations of the existing practices adopted in numerical simulation that mitigate this effect to a certain extent are identified. Two numerical models namely, the subcontrol volume model and the flow correction model, were proposed and developed to improve the mass balance. The subcontrol volume model improved the results with a little increase in computational efforts. The flow correction model completely eliminated the mass loss problem. The studies were conducted on two‐ as well as three‐dimensional preforms to confirm the accuracy and reliability of these numerical models. POLYM. COMPOS., 2010.