| Several methodologies are presented in this dissertation that aim to ensure successful filling of the mold cavity consistently, during the mold filling stage of Liquid Composite Molding (LCM) processes such as Resin Transfer Molding (RTM), Vacuum Assisted Resin Transfer Molding (VARTM) and Seemann Composites Resin Infusion Molding (SCRIMP).; Key parameters that affect the resin flow in the mold cavity can be divided into two main groups as continuum-related parameters and injection-related parameters. Flow continuum, which consists of all the spaces resin can reach in the mold cavity, has two major components: the porous medium, which is made up of the fiber reinforcements, and the flow channels that are introduced into the flow continuum unintentionally and offer an easy flow path to the resin. The properties that characterize the porous medium and the unintentional flow channels are continuum-related parameters. The injection-related parameters include resin injection locations (gates), resin injection conditions and air drainage locations (vents).; Modeling the flow continuum is crucial in predicting the resin flow in the mold cavity. In this study, permeability, the key property of the porous medium, is predicted using the Method of Cells, a proven method to predict macroscopic properties of heterogeneous materials. Unintentional flow channels, which are also called racetracking channels, are modeled using a probabilistic approach.; Injection-related parameters are the key tools to influence the resin flow in the mold cavity. In this study, Branch and Bound Search is modified for single gate optimization. Due to its pertinence to injection system design, the parameters that govern gate effectiveness in steering the resin advance are studied. A combinatorial search algorithm is proposed for vent optimization. Vent optimization and gate optimization algorithms are integrated for simultaneous gate and vent optimization.; Overall, these methodologies reduce the cycle time and reject ratio of LCM processes by providing an accurate and complete model of the flow continuum and optimal control-oriented injection design solutions, increasing the profitability and feasibility of the process. |
