Development of Liquid Composite Moulded Thermoset Composite Automotive Parts Using Process Simulations

Abstract

Hand layup method is normally used for manufacturing composite parts with large and complex geometry where as Resin Transfer Moulding (RTM) process is a better substitute, but is sparingly used due to lack of proper manufacturing technology. Developments of RTM manufacturing process always requires a proper mould design. In addition, difficulty in the tooling design and mould fabrication cost increases with increase in size and complexity of the component. The scale down strategy of full scale product avoids bigger size mould requirements, prototype bulk production for product testing and quality check at the starting phase of product development. Moreover, the mould scale down strategy can be used to validate the process and the product with less capital input. In this work, a methodology to develop a RTM technology for manufacturing a complex and large composite structure utilizing the process simulation were demonstrated using high speed cab front as selected component.