Numerical Simulation and VARTM Process for Manufacturing of Coir Mats

Abstract

A composite material is manufactured by combining two or more materials. The final product has properties different from the individual materials. Using coir fiber as a reinforcement in composite material has gained researchers’ attention due to its better physical, mechanical, and thermal properties. Vacuum Assisted Resin Transfer Molding (VARTM) is a manufacturing method for making large composite parts. This process uses an open mold to manufacture the composite material. This research uses the VARTM process and traditional hand lay-up methods to manufacture coir mats. The basic materials are coir fiber-reinforced natural rubber matrix resin. The produced bio-composite materials will be biodegradable with less impact on the environment. The VARTM process uses atmospheric pressure and room temperature to inject the resin into the mold. Therefore, the operation is easier to control. This process involves vacuum injection to remove air from the mold and fill the coir fiber with the natural rubber latex resin. Finally, VARTM coir mats and hand lay-up coir mats were tested to find their thermal properties, and the best-suited manufacturing method was selected for roofing insulation applications of buildings. Manufacturers can accurately forecast the filling time and flow front pattern of the natural fiber latex resin all around the mold by simulating the VARTM process with ANSYS software. This simulation allows for better control and optimization of the manufacturing process for coir mats, ensuring uniform quality and geometrical accuracy. ANSYS software provides a diversified platform to simulate the VARTM process, allowing manufacturers to analyze various parameters such as resin flow and pressure distribution inside the mold. By introducing ANSYS simulation into the manufacturing workflow, operators can learn about process optimization, material use efficiency, and potential areas for operation improvement. However, integrating ANSYS simulation with the VARTM process enhances the manufacturing of coir mats and aligns with industrial growth and efficient and sustainable production practices