Numerical Simulations of Carbon-Fibre Impregnation with a Polymer as an Anisotropic Permeability Medium

The impregnation process of carbon fibres with polymers is challenging to model due to the system’s complexity, particularly concerning the following aspects: the complex rheology of the polymeric matrices and the presence of solid, continuous fibres, both with anisotropic properties, and the interaction between solid and fluid, which can change the displacement of fibres into a cyclic dependence. In this work, an interesting approach was considered by setting the fibres as a porous medium whose properties were calculated with microscale/macroscale cycle modelling. In the microscale modelling stage, two main assumptions can be made: (i) a homogeneous distribution with a representative cell or (ii) a stochastic distribution of fibres. The solution to the abovementioned flow and fibre distribution problem can severely differ with only a slight change in a single parameter for a given set of processing parameters. Therefore, the influence of some of them during the fibre impregnation process was evaluated, allowing a shortcut for the polymer through a gap between fibres and the bottom wall of the extrusion die. The range of investigated values regarding the gap enables one to cover good impregnation conditions up to the occurrence of the shortcut and consequent poor impregnation quality. These studies were performed with numerical simulations with circa 126,000 degrees of freedom, considering the discretisation mesh elements and the unknowns (pressure and two velocity components).