New approach for filling simulations of dual-scale preforms used in the manufacturing of composites materials.

Some fibrous reinforcements used in the manufacturing of parts by Liquid Composite Molding (LCM) have a dual-scale nature, which supposes flow imbalances between the tows and channels at mesoscopic scale, which in turn, cause uncontrolled defects (voids, dry points, among others) and could considerably affect the global flow behavior during the filling of cavities at macroscopic scale. In the present work, a new approach to conduct filling simulations of dual-scale fibrous reinforcements at mesoscopic scale is proposed. This consists of prescribing a pressure gradient along the Representative Unitary Cell, and imposing Stokes-Darcy matching conditions between the tows and the channel sub-domains to determine the filling of the former ones. Contrarily to the traditional approach, where a uniform pressure is assumed for the channels and only the porous media fluid is modeled, the present one allows considering the fluid pressure gradient at channels (fluid motion), air compressibility and dissolution, flow-direction dependent capillary pressure, and vacuum pressure, as well as capturing several phenomena involved in the dynamic evolution of intra-tow voids, namely, compression, mobilization at constant volume and migration from tows towards channel. The velocity vectors and streamlines in the tows and channel subdomains, when these phenomena take place, are analyzed as well.