Process simulation for a large composite aeronautic beam by resin transfer molding

This paper presents the numerical process analysis and the experimental investigation for the manufacturing of a reinforced carbon-fiber demonstrator of a large aeronautic beam by resin transfer molding (RTM). The component is a primary structure characterized by several thick sections with abrupt changes in shape that complicates the resin impregnation of the preform. Process simulations based on a finite element method-modified control volume (FEM-CV) were conducted to investigate the resin flow front patterns and find the injection scheme that guarantees both a good impregnation of the preform and a filling time compatible with the resin gel time. The beam component was successfully manufactured, and a good agreement between the numerical analysis and the fabrication process was demonstrated.