Numerical simulation with experimental validation of the structural reaction injection moulding of 3D continuous fibre reinforced polyurethane foam

Abstract Sandwich composite materials are established in the industry. Polyurethane foam reinforced with spacer fabric represents an innovative solution for a core in this field. It is manufactured in the Structural Reaction Injection Moulding (SRIM). This paper describes new investigations that provide the base for component and process design when using this Interpenetrating Phase Composite (IPC). Filling studies were carried out for this purpose in three moulding tools with different cavities with and without spacer fabric. It is shown that the PUR foam expansion and the foam bulk density are clearly influenced by the sprue type, cavity design and spacer fabric. Simulations are necessary to investigate all process-structure-property relationships in detail and to enable a user-friendly and efficient design of material and process. Adequate mathematical models to simulate the transport of mass, heat and momentum in the SRIM are presented in this paper. The resistance to the expansion process caused by the porous structures in the domain were taken into account. The transport of momentum in the mould is described with the Navier–Stokes-Brinkman equations which in the limit of the permeability tensor reduces to the Navier–Stokes equation. The model equations are solved numerically and the results show reasonable agreement with the experimental data.