Huntsman Corporation · NYSE:HUN
Huntsman — 9th World Pultrusion Conference 2008
26 slides from Huntsman's conference presentation, Mar 27, 2008
Slide 1: CFD Modeling of the Closed Injection Wet-Out Process For Pultrusion
CFD Modeling of the Closed Injection Wet- Out Process For Pultrusion Michael Connolly Business Development Team Auburn Hills, MI, USA Mark Brennan Core Science Team Everberg, Belgium Huntsman Polyurethanes 9th World Pultrusion Conference European Pultrusion Technology Association Rome, Italy March 2
Slide 2: Outline
Outline Definition of Process Challenge CFD Model Assumptions Equations Boundary Conditions Building Process Resin Flow Patterns Predictions of Pressure Profiles Comparison with Experimental Data Conclusions Future Work 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 3: Typical PU Pultrusion Set-up
Typical PU Pultrusion Set-up What is happening What is the inside the box design? injection box? 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 4: Process Challenge
Process Challenge What is the internal design of the injection box? How can trial and error be eliminated/reduced? How can box design be optimized for particular parts and process conditions? Thick vs. thin Line speed Resin properties SOLUTION: Develop computational model Compare with detailed exper
Slide 5: CFD Model - Assumptions
CFD Model - Assumptions Micro-scale model of PU resin flow through fibers To model injection box at macro-scale we must use a phenomological approach Resin and reinforcement represented as a moving porous medium (extension of Darcy s law) Surface tension effects captured by permeability tensor Singl
Slide 6: CFD Model - Equations
CFD Model - Equations Navier-Stokes Equations u 0 2 u u p u S Source terms describing moving porous medium S u U K Injection box porosity changes with position 1 Vf ( z ) Gebart model of permeability 2Df2 3 Kz c (1 )2 5 2 2 C1D f Vf ,max Kx Ky 1 4 (1 ) 9th World Pultrusion Conference, Rome, Italy, M
Slide 7: Model Regions & Boundary Conditions
Model Regions & Boundary Conditions Resin Inlet p pinj 1 Rovings Entrance p patm 0 Rovings Awet 1 Aglass Model Exit w W pull Initial Die Section die 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 8: Building a CFD model - 1
Building a CFD model - 1 Build geometry 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 9: Building a CFD model - 2
Building a CFD model - 2 Build Mesh 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 10: Building a CFD model - 3
Building a CFD model - 3 Add Physics 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 11: Building a CFD model - Solve Simulation
Building a CFD model 4 Solve Simulation 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 12: Building a CFD model - 5
Building a CFD model - 5 Look at Results 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 13: Resin Flow Patterns
Resin Flow Patterns 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 14: Influence of Glass Fraction
Influence of Glass Fraction 60 0.5 Glass = 50% Glass = 50% Superficial Velocity (m/min) 50 Glass = 55% Glass = 55% 0.4 Glass = 60% Glass = 60% Pressure (barg) 40 Glass = 65% 0.3 Glass = 65% 30 0.2 20 0.1 10 0 0 -50 -40 -30 -20 -10 0 10 -50 -40 -30 -20 -10 0 10 Distance from die entrance (cm) Distanc
Slide 15: Influence of Glass Fraction
Influence of Glass Fraction 60 Pressure rise z = 0 in. z = -1 in. quadratic with z = -2 in. glass fraction 50 z = -4 in. More pronounced 40 at die face than at Pressure Rise (bar) transducer locations 30 20 10 0 0.45 0.5 0.55 0.6 0.65 0.7 Glass Fraction (-) 9th World Pultrusion Conference, Rome, Ita
Slide 16: Pressure Rise in the Injection Box
Pressure Rise in the Injection Box 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 17: Tapered Injection Box Setup
Tapered Injection Box Setup Resin Injection Port Digital (Top & Bottom) Pressure Transducer at 5 cm from Die Face ROVINGS 120 4400-Tex PPG 2026 Digital Pressure Toggle Clamp and Transducer Mounting Bracket (with alignment pins) at Tee Inlet 9th World Pultrusion Conference, Rome, Italy, March 26-28,
Slide 18: Pressure Profiles in the Injection Box
Pressure Profiles in the Injection Box Pressure rises faster than model prediction 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 19: Comparison with Experiments
Comparison with Experiments Lower viscosity data Small variation with line speed Capillary forces now dominate? Simulation predictions lower than experimental data Rate of rise in pressure higher 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 20: Void Fraction
Void Fraction Shorter Injection Box Higher Glass Fraction Resin Air Void % 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 21: Conclusions
Conclusions Model inputs include: Improvements needed: Injection box geometry Improved permeability Number & location of ports parameters Injection pressure Do additional Line speed experimental Resin viscosity & density, measurements glass fraction & density Do small-scale flow Permeability defined
Slide 22: Future work
Future work Micro-scale modeling Surface tension effects Viscosity Experimental Permeability measurements Pultrusion trials New Materials CFM Engineered fabric New Geometries Thicker parts Round parts Consolidated wet-out Cure/Exotherm Mapping 9th World Pultrusion Conference, Rome, Italy, March 26-2
Slide 23: 2D Pultrusion Die Modeling
rusion Technology As Enriching lives through innovation 2D Pultrusion Die Modeling
Slide 24: Die Exotherm: 6mm Thick Profile
Die Exotherm: 6mm Thick Profile Zone 1 = 330 F (165 C) 12 IPM Core 425 18 IPM Core 400 TC 1 TC 2 24 IPM Core 375 External Temp @ 12 IPM 350 External Temp @ 18 IPM 325 External Temp @ 24 IPM 300 Temperature (°F) Injection box 275 Cooling 250 225 Exit of Die 200 175 Cooling 150 Zone 1 Zone 2 125 100 7
Slide 25: Cure/Exotherm Mapping: 6 mm Profile
Cure/Exotherm Mapping: 6 mm Profile 18 IPM, Zone 1=330 F (45.7 cm/min, 165 C) 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008
Slide 26: Questions???
Questions??? 9th World Pultrusion Conference, Rome, Italy, March 26-28, 2008