An integrated approach for modeling the injection, compression, and resin transfer molding processes for polymers

An integrated finite element process simulator has been developed for modeling the injection, compression, and resin transfer molding processes for polymeric materials. The similarities among the three processes permit consolidation of the models into an integrated software package with low maintenance and ease of future extension. An introduction to the integration algorithm embedded in the process simulator is followed by models for injection, compression, and resin transfer molding. The validation of the injection molding portion of the integrated simulator is then addressed by comparing pressure history and filling patterns between the simulator predictions and experimental data. Tooling, processing, and quality issues—such as gating and venting design, weldline locations, and pressure and closing force requirements—are illustrated by two examples, a 3‐D fan blade and a ribbed box.