Title: Simulation of core treatment and runner optimisation of sandwich composites in VARI process

Authors: Wantao Guo; Rongshan Zhou; Yibo Wu; Haochang Guo; Helezi Zhou

Addresses: Luoyang Ship Material Research Institute, Luoyang, 471000, China ' State Key Laboratory of Material Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan, 430000, China ' Luoyang Ship Material Research Institute, Luoyang, 471000, China ' Luoyang Ship Material Research Institute, Luoyang, 471000, China ' State Key Laboratory of Material Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan, 430000, China

Abstract: This study employs simulation to analyse the resin impregnation process of sandwich materials, aiming to optimise resin flow process parameters and core material treatment to enhance product quality and reduce costs. Simulations were conducted to assess the effect of runner positions, injection line spacing, and gap treatment on resin flow behaviour. The results indicate that a design with slots at the bottom of the core is more effective in reducing defects within the sandwich panel. Additionally, the simulation outcomes demonstrate that appropriate line spacing and gap treatment are crucial for controlling the flow front and minimising air trap phenomena. This work utilises HfCAE3.0 and employs compressible two-phase flow model to effectively simulate the flow of gas and liquid phases during the injection process. It also provides theoretical guidance and optimisation suggestions for process parameters, which can enhance the performance of composite materials in applications such as shipbuilding and aerospace.

Keywords: sandwich composites; vacuum assisted resin infusion; numerical simulation; process optimisation.

DOI: 10.1504/IJVSMT.2025.150172

International Journal of Vehicle Systems Modelling and Testing, 2025 Vol.19 No.4, pp.432 - 452

Received: 14 Jan 2025
Accepted: 12 Apr 2025
Published online: 02 Dec 2025 *

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