The optimization process of vacuum infusion process to bond pultruded plates for spar cap manufacturing was established by numerical simulation, and the influence of process parameters on fabrication efficiency and quality was analyzed. Firstly, the permeability of fibrous fabrics, the fiber volume content and the temperature-viscosity relationship of the epoxy resin were determined experimentally. Then the numerical model of the spar cap was established, and the mesh size was determined by sensitivity analysis. Finally, the effects of pultruded plate arrangement spacing and residual vacuum pressure on the molding process were investigated parametrically. The results show that the deviation of the flow front position and mold filling time obtained from the simulation is less than 7% from the full-scale experiment. The mold filling efficiency is the highest when the spacing of the pultruded plate arrangement is 0.3 mm, and the porosity is less than 2% when the residual vacuum pressure is less than 4000 Pa, which proves the feasibility and accuracy of the numerical optimization method.
Key words
composite materials /
wind turbine blades /
numerical analysis /
pultruded spar cap /
VARI
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