2020 10 01 Pam-Rtm

PAM-RTM training
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ESI Group
September 2020
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Copyright © ESI
Copyright
Group, ©
2015.
ESI Group,
All rights
2015.
reserved.
All rights reserved.
Exercice 1
Injection 1D – RTM – Solution analytique
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Copyright © ESI Group, 2015. All rights reserved.
1D – rectilinear flow
Darcy’s Law
• If the flow is rectilinear (so that the fluid velocities in both y and z directions are 0),
the Darcy’s Law is reduced to the following expression:
Pinj
𝑄𝑥 𝐾 𝑑𝑃
𝑢𝑥 = =− Resin Flow
𝐴 𝜇 𝑑𝑥 x dx
Mass Conservation
‣ : Fluid velocity in direction;
‣ A: cross sectional area of the cavity,
𝑑 𝑢𝑥
=0 constant
𝑑𝑥 ‣ K: Reinforcement permeability, constant
‣ : Fluid viscosity, constant
‣ P: Pressure
A linear pressure distribution

𝑑 𝐾 𝑑𝑃
𝑑𝑥 𝜇 𝑑𝑥(=0 ) between the injection gate and the
flow front.
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1D – rectilinear flow
Constant pressure
• Pressure Distribution: ‣ : Resin pressure at injection

) gate;
‣ : Position of flow front
• Macroscopic fluid velocity: ‣ : Reinforcement Porosity
‣ : time required for the resin
𝑢𝑥 𝐾 𝑃 𝑖𝑛𝑗
𝑣𝑥 = = to reach a particular point
𝜑 𝜑𝜇 𝑥 𝑓𝑓 within the mould
Reciprocal Integration
𝜑𝜇
𝑡 𝑓𝑓 = 𝑥 2𝑓𝑓
2 𝐾 𝑃 𝑖𝑛𝑗
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1D - Rectilinear Flow
Constant flow rate
• Filling time from the total reinforcement pore volume:

𝜑 𝐴 𝑥 𝑓𝑓
𝑡 𝑓𝑓 =
𝑄 𝑖𝑛𝑗
• Pressure at injection gate:

𝑄𝑖𝑛𝑗 𝜇 𝑥 𝑓𝑓
𝑃 𝑖𝑛𝑗 =
𝐴𝐾
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1D - Rectilinear Flow
• Assess the final filling time for the following conditions:

‣ Constant ΔP = 10 bar + resin viscosity = 0,5 Pa/s + preform permeability = 10-10 m² +
preform fiber content = 60% - (RTM process with thermoset resin)
‣ Constant ΔP = 1 bar + resin viscosity = 0,5 Pa/s + preform permeability = 10-10 m² + preform
fiber content = 60% - (INFUSION process with thermoset resin and without flow media)
‣ Constant ΔP = 10 bar + resin viscosity = 0,5 Pa/s + preform permeability = 10-13 m² +

preform fiber content = 60% - (RTM process with thermoset resin and compact UD)
‣ Constant ΔP = 10 bar + resin viscosity = 0,5 Pa/s + preform permeability = 10-8 m² + preform
fiber content = 60% - (flow media in infusion process)
‣ Constant ΔP = 10 bar + resin viscosity = 500 Pa/s + preform permeability = 10-10 m² +

preform fiber content = 60% - (RTM process with thermoplastic resin)
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Exercice 1
Injection – RTM – Simulation EF
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Case_01a
Case_01a: linear injection of a rectangular plate with vent
Objective >> be aware of the basic workflow for RTM process simulation
Model setup >> Simulation type Filling
>> Material property • Resin: Resin_New_1

definitions Viscosity = 0.1 Pa·s
• Reinforcement: Preform
permeability K1,K2,K3 = 1E-10 m2
>> Material assignment • Part:

related Material=Preform
Porosity=0.5
Thickness=0.005 m
>> Boundary condition • Region “pressure”

definitions pressure = 1E5 Pa
state = 1 (open=1, close=0)
• Region “vent”
pressure = 0
Data >> original
>> reference Case_01a.vdb
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Case_01a Open File
• Launch Visual-Environment
• Select the Composites and Trade in the

Application Manager
• Set the Default application to RTM
• Open File Case_01a
Case_01a Overview
Case_01b step by step
• Check Simulation type =
Filling in Simulation
parameters inside RTM folder
Case_01a Set parameters
• Click on Database/Material
• Right click “All/Resin” to edit Resin_New_1
• Define General Property for resin as the image
• Click Save and then Close
Note: Resin density needs to

be defined in any case for filling
simulation or filling doesn't run
properly, although density is
taken into account in thermal
process and the cases with
gravity activated .
• Right click Reinforcement to edit Preform
• Define General Property for Preform:

permeability
• Click Save
• Click Close
• Select Injected Resin in
Simulation parameters inside
RTM folder
• Select (or check if already attributed) the reinforcement in Layer Design Manager
‣ Database = User or Model
‣ Name = Preform (or the name you give in material Database to the preform)
‣ Right click on Reinforcement case and select it
1 2
• Select “Process Condition/Pressure_1”
from the tree on the left
• Modify the Pressure value
• Apply and close
note: Temperature of resin has a default value (300 K), but this value is
not used in this simulation because at the beginning of this case the
simulation type has been set as an isothermal injection simulation.
• Select “Process Condition/Vent_1” from
the tree on the left
• Verify the Pressure value and State
• Apply and close
• Check the region where pressure and vent are located
Click on
Pressure_1
Click on
Vent_1
Case_01a Run simulation
• Select “File/Save” to save the model
with a name (e.g. Case_01a), then
a .vdb file is generated
• Run the computation with “RTM/Start

Simulation”
• Define the Number of Processors as

1
• Define Solver path to: C:\Program

Files\ESI Group\PAM-COMPOSITES\
2016.0\PAM-RTM\DMP
Note: The solver path need to be updated according

to the actual PAM-RTM installation path.
Select Save VDB to save the .vdb file automatically
when file is submitted to the solver. If the toggle is ON,
the .vdb file is saved, and if it OFF, it is not saved.
Click Log… and the log file will be opened
• Click Run
Case_01a Load Results
• Select “RTM/Load Result”, the
GUI will switch to Visual-Viwer
• The result file
Case_01a_RESULT.erfh5
• is loaded
Case_01a Check results
• Display filling contour with

“Results/Contour”
• Select FILLING_TIME in NODE folder
• Select Smeared in Contour On/Off
section
• Check Min/Max ID to show the nodes
• Select FILLING_FACTOR in
NODE folder
• Go step by step by clicking
in Animation toolbar
• Create an animation by
clicking in Animation
toolbar
• Modify the speed of animation
by clicking in Animation
toolbar
• Move up and down the cursor
to modify the speed of
animation
• Stop the animation by clicking
in Animation toolbar
• Double click the contour to
open Spectrum Control
window
• Set the Levels of colors to 10
• Click Close
• Select All Nodes to show on
Case_01a Test
• Modify permeability and compare the filling time with the

previous result and the analytical ones
Exercice 2
Injection 1D – RTM – Simulation EF
Perméabilité moyenne
Equivalent permeability in flow parallel to layers
Equivalent permeability in flow parallel to layers
Equivalent permeability in infusion process with flow media and
reinforcement (1)
Pin = 1 bar A Pout = 0 bar
• Resin viscosity : 0,1 Pa/s
• Reinforcement thickness: 1 mm
Reinforcement : K = 10-11
• Flow media thickness : 0,1 mm
1m
• Filling time for case A ?
B
• Equivalent permeability for case B ?
• Filling time for case B ? Flow media : K = 10-8
Reinforcement : K = 10-11
Exercice 3
Injection 1D – RTM – Simulation EF
Effet d’un chemin préférentiel
Ou
Infusion – section 2D – effet du drainant (flow media) sur le

front d’injection
Case_01b
Case_01b: linear injection of a rectangular plate with vent and edge effect
Objective >> be aware of edge effect in RTM process and its corresponding setting in simulation
New in this case

• added Reinforcement and Part for Channel
(compared to Case_01a)
>> Material property definitions • Resin: Resin_New_1

Viscosity = 0.1 Pa·s
• Reinforcement: Preform
type = fabric
• Reinforcement: Channel
type = fabric

related Material=Preform
Porosity=0.5
Thickness=0.005 m
• Part:
related Material=Channel
Porosity=1 (i.e. empty channel)
Thickness=0.005 m
>> Boundary condition • Region “pressure”

definitions pressure = 1E5 Pa
• Region “vent”
pressure = 0
Data >> original Case_01b_start.vdb
>> reference Case_01b.vdb
31
Case_01b Open file
• Switch the Default application to

RTM
• Click OK
Case_01b Open file
• Select “File/Open”
• Switch the Files of type to VDB

files
• Select Case_01b.vdb to import

the mesh
• Click Open
• Switch to Top View with Views toolbar
Channel
Reinforcement
Case_01b Simulation parameters
• Check simulation parameters
Case_01b Orientations
• Check orientation with “RTM/Part Orientation”
• Click ORIENTATION_2D_1
• Check e1 box
• Check e1 orientation is aligned with ‘x’ direction
Case_01b Set permeabilities
• Click on Preform on the tree
• Modify the permeability
• Click on Channel
• Modify the permeability
• Click Save
• Click Close
Case_01b Process conditions
• Select “RTM/Process Condition”
• Edit Pressure
Pressure=1E+5 (Pa), State=1
• Edit Vent
Pressure=0 (Pa), State=1
Pressure BC Vent BC
Case_01b Results
• Run the computation with “RTM/Start
Simulation”
• Load the ERF File with “Load Result”
• Visualize the FILLING_FACTOR result
Notice how the resin flows more easily along

the top edge (Channel zone)
Case_01b Test
• Modify the channel permeability and note the effect in the filling time
• Compare the results with the previous ones obtained with equivalent
permeability (exercice 2). What conclusion can you made ?
Exercice 4
Injection centrale 2D – RTM – Simulation EF
Anisotropie de la perméabilité
Flow Modeling
Darcy’s Law in 3D
Fluid Mechanics in porous medium
Permeability Tensor
Case_02b
Case_02b: Orthotropic central injection of a square plate with vent
Objective >> be aware of orthotropic permeability in RTM process and corresponding setting in simulation
>> be aware of Vent boundary condition defined in Visual-RTM
New in this case • preform orthotropic permeability taken into account
(compared to Case_02a) • 4 vent boundary conditions added
 (in following slides): identifying related new operations in Visual-RTM
>> orthotropic • Preform fiber orientations definition in Visual-RTM

permeability effect
>> Material property • Resins: Resin1
• Reinforcement: Preform2
type = fabric
permeability K1 = 3E-9 m2

related Material=Preform2
Porosity=0.824
Thickness=0.005 m
>> Boundary condition • region “pressure”

definitions pressure = 5E+5 Pa
• region “Vent_1” to “Vent_4”
pressure = 0
Data >> original Case_02a_start.igs or Case_02a.vdb

Case_02b Open file
• Open Case_02b.vdb
Case_02b Set permeability
• Click Reinforcement edit the permeability of Preform2
• Click Save
• Click Close
Case_02b Set process condition
• Select “RTM/Process
Condition”
• Check the four Vents and

their location
Vent_1 Vent_2
Vent_4 Vent_3
Case_02b Simulation results
• Save this model as a new one (e.g.

Case_02b.vdb)
• Run the calculation with “RTM/Start

Simulation”
• Load the ERF Files with “RTM/Load Result”
• Visualize the FILLING_FACTOR, FILLING_TIME

and PERMEABILITY results
note:
In this case, the preform permeability is not isotropic any
more which results in the flow front is not a circle as in
isotropic case but an ellipse
K1 being larger than K2, the resin flows more easily in
direction K1.
Note the resin arrival time on Vent_2 and Vent_4: 32 s. It is
needed for next case.
PERMEABILITY1
• Select PERMEABILITY1 in
SHELL section
• Check Vectors/Tensors
Note: Currently it is not possible to
visualize permeability orientation in
Visual-RTM, but it can be visualized
in ERF results file with Visual-Viewer.
PERMEABILITY2
• Modify the permeability in order to obtain a filling time:

‣ On vents 1 and 3 around 150 seconds
‣ On vents 2 and 4 around 30 seconds
Exercice 5
Injection centrale 2D – RTM – Simulation EF
Importance du contrôle des évents pendant l’injection
Case_02c
Case_02c: Orthotropic central injection of a square plate with varying vent state
Objective >> understand Vent role in RTM simulation
New in this case • vent_2 and vent_4 closed after resin has reached
(compared to Case_02b)  (in following slides): identifying related new operations in Visual-RTM
>> orthotropic permeability • Preform fiber orientations definition in Visual-RTM

effect
>> Material property • Resins: Resin1

• Reinforcement: Preform2
type = fabric

related Material=Preform2
Porosity=0.824
Thickness=0.005 m
>> Boundary condition • region “pressure”

definitions pressure = 5E+5 Pa
• region “Vent_1” and “Vent_3”
pressure = 0
• region“Vent_2” and “Vent_4”
pressure = 0
state = 10 (open=1, close=0)
Data >> original Case_02a_start.igs or Case_02b.vdb
>> reference Case_02c.vdb
Case_02c Open file
• Open Case_02c.vdb
• Right click or double click on Vent_2

to Edit it
• Check the values into the X-Y table
note: according to this piecewise line, the
Vent _2 opens at the beginning till 32s when
the resin has just reached Vent_2, then
closed till the injection complete
• Do the same with Vent_4
• Click Finish
Case_02c Results
• Save this model as a new one (e.g.
Case_02c)
• Run the calculation with “RTM/Start

Simulation”
• Switch to Viewer with

“Applications/Viewer
• Load the ERF Files of Case_02b and Case_02c Case_02b

Case_02c with “File/Open”
• Visualize the PRESSURE result
Note: For Case_02b, Vent_2 and Vent_4 always

remain open, so the pressures nearby is ZERO
during the whole filling process. While for
Case_02c, Vent_2 and Vent_4 are closed once
resin reaches, so the pressure nearby is Non-
zero and increases with the filling process
Case_02c Case_02b
Case_02c Results
• Select the window with loading
Case_02b_RESULT.erfh5 and Select
“File/Import and Plot”
• Pick a node near the Vent_2
• Select PRESSURE for the Ordinates (keep all
the display settings as default)
• Click Plot
• Click Close
• Select the window with loading
Case_02c.erfh5 and Select “File/Import
and Plot”
• Pick the same node near the Vent_2
• Select PRESSURE for the Ordinates
• Check Current Page, Current Window and
All curves in one plot
• Click Plot
• Click Close
Case_02c Results
• Doubt click on the legend
and open the Legends and
Labels window
• In the Legends section, input

the name of the legends
• Click Close
Exercice 6
Whole RTM process analyses of a fuselage part with complex
layup :
Pre-heating analysis
Heated injection analysis
Curing
Case_12 Overview
• Case_12 series:
Whole RTM process analyses of a fuselage part with complex layup
Description objective
Case_12a Mold preheating analysis • awareness of Preheating simulation in Visual-RTM
Case_12b Non-isothermal injection analysis • awareness of Heated RTM simulation in Visual-RTM
Case_12c Curing analysis • awareness of Curing simulation in Visual-RTM
Notes:
>> a typical solution is to simulate the RTM process stage by stage:
Case_12a  Case_12b  Case_12c
Copyright © ESI Group, 2015. All rights reserved. 85
Case_12a
Case_12a: Preheating analyses of a fuselage part
Objective >> to learn how to design the lay-up for laminates and define the specific heat and
conductivity by look-up table
Model setup >> Simulation type Preheating
>> Material property • Reinforcement:
definitions Preform8:
type = fabric
density = 1800 kg/m3
thermal conductivity K1= 6.83 W/ (m·K)
K2 =K3 = 1.5 W/ (m·K)
specific heat 1130.42 J / (kg·K)
Runner:
K1=K2=K3= 1.5 W/ (m·K)
specific heat = 1130.42 J / (kg·K)
>> Material assignment • Part “Stringer”, “Skin”:

related Material = Preform8
Porosity = 0.4
Thickness = 0.3125mm
• Part “Flow-media”:
related Material = Runner
Porosity = 0.8
Thickness = 1mm
>> Boundary condition • Region “Temperature”

definitions F(t)
• Region “Convection”:
Ref_Temp=298.15 (K); Convection Coeff=5 (W/m^2-K)
Data >> original Case_12_start.vdb
>> reference Case_12a.vdb
Case_12a step by step
• Set Default application to RTM
• Click OK
• Select File/Open to open a .vdb file

• Open Case_12_start.vdb file
• Select RTM/Simulation Parameters

• Set the simulation type to Preheating
• Set the Process Duration to 7200s
• Max time Step to 100s
• Click Apply
• Click Close
• Select RTM/Process Condition
• Switch the Type to Temperature
• Pick the Element face of the bottom

surface of Part_6
• Click Apply
• Click Close
• Set the Temperature type to F(t)
• Click to create a new function
• Input the data for the function
• Click Finish
• Click Apply
• Switch the Type to Convection
• Click to define region
• Select the element surface (refer to the

reference model)
• Click Apply
• Click Close
• Set the Reference Temperature to 298.15
• Set Convection Coefficient to 5
• Click Apply
• Click Close
• Save this model as a
new one (e.g.
Case_12a.vdb)
• Run the calculation

with “RTM/Start
Simulation”
• Load the ERF Files with

“RTM/Load Result”
• Visualize the
Temperature result
Case_12b
Case_12b: Non-isothermal injection analyses of a fuselage part
Objective >> to learn how to simulate heated filling in a complex part
Model setup >> Simulation type Heated Filling

>> Material property •Resin: Resin3
definitions density = 1265 kg/m3
viscosity = 0.1 Pa.s
thermal conductivity defined by LUT
specific heat defined by LUT
•Reinforcement:
Preform8:
type = fabric
Permeability: K1=6E-12 m2, K2=K3=6E-13 m2
Runner:
Permeability: K1=K2=K3=1E-9 m2

Porosity = 0.4
Porosity = 0.8
Thickness = 1mm
>> Boundary condition • Region “Temperature”, “convection”, “Pressure” and “Vent”

definitions
• Open Case_12a.vdb
• Change Simulation Type to Heated

Filling
• Switch Database for resin to User
• Click to create a new material
• Right click Resin to create New Material
• Name the resin as Resin3
• Input the General properties for Resin3
• Switch to Thermal section
• Set the type of Conductivity to F(T,

alpha)
• Set the Temperature count to 3
• Input the values in the table for different temperature
• Click OK
• Set the type of Specific Heat to F(T,
alpha)
• Set the Temperature count to 3
• Input the values in the table for

different temperature
• Click OK
• Switch to Chemical
section
• Define the Chemical

properties for Resin3
• Click Finish
• Click Save
• Click Close
• Set the Resin3 as

Injected Resin
• Click Apply
• Click Close
• Right click Parts in Explorer
• Select Extract/Mapping
• Check Mapping
• Click to open a *g.unf file
• Open Case_12ag.unf file
• Input 70 in Step (the last step)
• Click Mapping
• Check Display to show the

distribution of temperature
• Click Close
• Select RTM/Process
Condition
• Switch the Type to

Pressure
• Click to define
region
• Pick the Element face
• Click Apply
• Click Close
• Set the Temperature

to 353.15 K
• Click Apply
• Switch the definition type to Vent
• Select the element face to create Vent_1
• Click Apply
• Click Close to exit the define region
• Set the Vent Pressure to 2000 Pa
• Click Apply
• Select the element face from
the top surface of Stringer-1 to
create Vent_2
• Click Apply
• Click Close to exit the define

region
Vent_5
• Set the Vent Pressure to 2000
Pa
Vent_4
• Click Apply
• Similarly, the vent_3, vent_4
and vent_5 are create by the Vent_2
same way
Vent_3
• Right click on Trigger to create new triggers
• Set Triggers Type to On Outlet
• Select Vent_2 in selection list
• Click OK
• Click to confirm selection
• Set Injected volume value to 2e-5
• Click Apply
• Similarly, create trigger_2, trigger_3 and
trigger_4 with the same type, lost volume.
The corresponding process condition is:
Trigger2 -> Vent_3
Trigger3 -> Vent_4
Trigger4 -> Vent_5
• Right click on Vent_2 to Edit it
• Check Trigger in Selection section
• Pick Trigger_1 in Selection List
• Click OK
• Click to confirm selection

• Set the State to 0, it means process
condition will be closed at trigger
activation
• Click Close
• Click Apply and then Close Process

Condition box
• Similarly, activate trigger for the other vent process conditions and define the state.
Vent_3 Vent_4 Vent_5
new one (e.g.
Case_12b.vdb)

with “RTM/Start
Simulation”

• Visualize the
Filling_Time, Cure
result
• To execute the volume cut
• Menu bar -> Sections -> Volume Cut
• Invoke Results -> Contour -> Filling
Time
• The bounding box will be launched
• The attached video shows the volume cut operation
Case_12c
Case_12c: Non-isothermal injection analyses of a fuselage part
Objective >> to learn how to simulate Curing in a complex part
Model setup >> Simulation type Curing
>> Material property definitions •Resin: Resin3
viscosity = 0.1 Pa.s
thermal conductivity defined by LUT
specific heat defined by LUT
•Reinforcement:
Preform8:
type = fabric
thermal conductivity K1= 6.83 W/ (m·K)
K2 =K3 = 1.5 W/ (m·K)
specific heat 1130.42 J / (kg·K)
Runner:
K1=K2=K3= 1.5 W/ (m·K)
specific heat = 1130.42 J / (kg·K)

Porosity = 0.4
Porosity = 0.8
Thickness = 1mm
>> Boundary condition definitions • Region “Temperature”, “convection”
>> reference Case_12c.vdb
Case_12c step by step
• Open Case_12a.vdb
• Set the simulation type to Curing
• Set the Process Duration to 18000
• Max time step to 100
• Keep other set-up default
• Click Apply
• Click Close
• Right click Parts in Explorer
• Select Extract/Mapping
• Check Mapping
• Click to open a *g.unf file
• Open Case_12bg.unf file
• Input 41 in Step (the last step)
• Click Mapping
• Check Display to show the mapping

results of the variables in drop-down list
• Click Close
• Right click Process
Conditions/Temperature_1 in
explorer tree to Edit it
• Input the new data in the table
• Click Finish
• Click Apply
• Click Close
• Right click Process Conditions
/Convection_1 in explorer tree to Edit it
• Set the Reference Temperature type to F(t)
• Click to create a new function
• Input the data for the function
• Click Finish
• Click Apply
• Click Close
new one (e.g.
Case_12c.vdb)

with “RTM/Start
Simulation”

• Visualize the Cure,

Temperature result
Case_12c Test
• Modify the temperature condition

• Compare the results
T H A N K YO U !
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2015. All rights reserved.

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PAM-RTM training

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A linear pressure distribution

• Pressure Distribution: ‣ : Resin pressure at injection

• Filling time from the total reinforcement pore volume:

• Pressure at injection gate:

• Assess the final filling time for the following conditions:

‣ Constant ΔP = 10 bar + resin viscosity = 0,5 Pa/s + preform permeability = 10-13 m² +

‣ Constant ΔP = 10 bar + resin viscosity = 500 Pa/s + preform permeability = 10-10 m² +

Model setup >> Simulation type Filling

>> Material property • Resin: Resin_New_1

>> Material assignment • Part:

>> Boundary condition • Region “pressure”

Data >> original

>> reference Case_01a.vdb

• Select the Composites and Trade in the

• Set the Default application to RTM

• Open File Case_01a

• Right click “All/Resin” to edit Resin_New_1

• Define General Property for resin as the image

• Click Save and then Close

Note: Resin density needs to

• Define General Property for Preform:

• Modify the Pressure value

• Apply and close

• Verify the Pressure value and State

• Apply and close

• Run the computation with “RTM/Start

• Define the Number of Processors as

• Define Solver path to: C:\Program

Note: The solver path need to be updated according

Click Log… and the log file will be opened

• Display filling contour with

• Modify permeability and compare the filling time with the

Infusion – section 2D – effet du drainant (flow media) sur le

New in this case

Model setup >> Simulation type Filling

>> Material property definitions • Resin: Resin_New_1

>> Material assignment • Part:

>> Boundary condition • Region “pressure”

Data >> original Case_01b_start.vdb

>> reference Case_01b.vdb

• Switch the Default application to

• Switch the Files of type to VDB

• Select Case_01b.vdb to import

• Switch to Top View with Views toolbar

• Check e1 orientation is aligned with ‘x’ direction

• Load the ERF File with “Load Result”

• Visualize the FILLING_FACTOR result

Notice how the resin flows more easily along

Model setup >> Simulation type Filling

>> orthotropic • Preform fiber orientations definition in Visual-RTM

>> Material assignment • Part:

>> Boundary condition • region “pressure”

Data >> original Case_02a_start.igs or Case_02a.vdb

• Check the four Vents and

• Save this model as a new one (e.g.

• Run the calculation with “RTM/Start