PSI - Issue 66

236 8

Mohammad Jameel Ziedan et al. / Procedia Structural Integrity 66 (2024) 229–246 Author name / Structural Integrity Procedia 00 (2024) 000–000

2. Vacuum Forming Vacuum forming of composite materials is a manufacturing process in which a composite material is shaped by applying vacuum pressure with heat assistance. In this process, the composite material is placed over a mold, and a vacuum is created between the mold and the material. The atmospheric pressure then presses the material against the mold surface, causing it to take the shape of the mold. This method is commonly used to produce lightweight and strong components with complex shapes, making it popular in industries such as aerospace, automotive, and marine engineering (Afshariantorghabeh et al., 2023; Grankäll et al., 2021; Jones et al., 1995). 2.1. Vacuum-Assisted Resin Infusion Molding (VARIM) VARIM is a manufacturing process for creating composite materials by infusing resin into dry reinforcement materials like fiberglass or carbon fiber. The process involves mold preparation, laying up reinforcement materials, creating resin channels and vacuum lines, vacuum bagging, resin infusion, curing, and finishing. VARIM offers advantages such as improved resin distribution control, reduced cycle times, and high-strength composite parts (Kedari et al., 2011, 2011); see Fig. 6. Divided into zones with independent temperature control, the system employs a Programmable Logic Controller (PLC) to adjust temperatures and curing cycle intervals. Ensuring even temperature distribution is crucial for composite part production, ensuring consistent curing conditions across all zones. The PLC allows for adaptable control to adjust curing conditions, enhancing system flexibility. Monitoring real-time temperature values from all zones and logging them for data analysis optimizes the properties of the composite samples.

Fig. 6. Schematic illustration of the vacuum assisted resin infusion molding (VARIM) process (Goren & Atas, 2008).

Fig. 7. Schematic explains the difference between the typical VARTM process and the modified VARTM process (Menta et al., 2014).

Three cooling methods (air cooling, air-water cooling, water cooling) were examined to evaluate their effects on processing time, residual strains, and mechanical properties. By monitoring residual strains with embedded strain gauges, it was proposed gradual cooling pre-glass transition temperature and swift cooling post-transition for effective