A level set approach for the analysis of flow and compaction during resin infusion in composite materials

Fluid flow and fabric compaction during vacuum assisted resin infusion (VARI) of composite materials was simulated using a level set-based approach. Fluid infusion through the fiber preform was modeled using Darcy’s equations for the fluid flow through a porous media. The stress partition between the fluid and the fiber bed was included by means of Terzaghi’s effective stress theory. Tracking the fluid front during infusion was introduced by means of the level set method. The resulting partial differential equations for the fluid infusion and the evolution of flow front were discretized and solved approximately using the finite differences method with a uniform grid discretization of the spatial domain. The model results were validated against uniaxial VARI experiments through an [0]8 E-glass plain woven preform. The physical parameters of the model were also independently measured. The model results (in terms of the fabric thickness, pressure and fluid front evolution during filling) were in good agreement with the numerical simulations, showing the potential of the level set method to simulate resin infusion.