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Meso-scale process modelling strategies for pultrusion of unidirectional profiles

Yuksel, Onur; Baran, Isnet; Rasmussen, Filip Salling; Spangenberg, Jon; Ersoy, Nuri; Hattel, Jesper; Akkerman, Remko


Onur Yuksel

Isnet Baran

Filip Salling Rasmussen

Jon Spangenberg

Nuri Ersoy

Jesper Hattel

Remko Akkerman


The resin injection pultrusion is an automated composite manufacturing method in which the resin is injected in a chamber. The flow and the thermo chemical mechanical (TCM) models have been studied for the pultrusion process to improve the reliability of the final products. Flow models are needed to understand and describe the fiber impregnation, filling time and presence of dry spots or voids. Also pressure field in the injection chamber can be estimated with flow models. TCM models are needed to predict residual stress distributions and to optimize the process conditions. A non-uniform fiber distribution strongly affects the results of both types of models. In this study, different strategies are carried out to implement non-uniform fiber distributions into the models. The cross-sectional image and fiber distribution of a 19×19 mm glass fiber reinforced polyester unidirectional pultruded composite is used. Non-uniform fiber distribution is observed and implemented into the flow model by means of permeability variations. The results of this study are compared with uniform fiber distribution results. In the TCM model, the non-uniform fiber volume content is implemented within different sized patches. The results show that the non-uniform fiber fraction should be taken into account for the process models of composites in order to capture the local process induced stresses and probability of dry spots or voids due to poor fiber impregnation.

Onur Yuksel1,2,4, Ismet Baran1,5, Filip Salling Rasmussen3, Jon Spangenberg3, Nuri Ersoy2, Jesper H. Hattel3 and Remko Akkerman1


Yuksel, O., Baran, I., Rasmussen, F. S., Spangenberg, J., Ersoy, N., Hattel, J., & Akkerman, R. (2018, June). Meso-scale process modelling strategies for pultrusion of unidirectional profiles. Paper presented at ECCM18 - 18th European Conference on Composite Materials, Athens, Greece

Presentation Conference Type Conference Paper (unpublished)
Conference Name ECCM18 - 18th European Conference on Composite Materials
Conference Location Athens, Greece
Start Date Jun 24, 2018
End Date Jun 28, 2018
Acceptance Date Jun 24, 2018
Deposit Date Jan 24, 2019
Peer Reviewed Not Peer Reviewed
Keywords pultrusion, fiber distribution, process model, permeability, residual stress
Public URL
Additional Information Title of Conference or Conference Proceedings : ECCM18 - 18th European Conference on Composite Materials Athens, Greece, 24-28th June 2018