Statistical Analysis of Uncertainties in Deterministic Computational Modeling - Application to Composite Process Resin Infusion Flow Model

Deterministic physics-based flow modeling provides an effective way to simulate and understand the resin flow infusion process in liquid composite molding processes and its variants. These are effective to provide optimal injection time and locations prior to gelation for given process parameters of resin viscosity and preform permeability. However, there could be significant variations in these two parameters during actual manufacturing. This paper presents simulation-based statistical analysis of uncertainties of these process parameters involved in the resin flow infusion. Two key process parameters, viscosity and permeability, and their statistical variations are examined individually and subsequently in combination for their impact on the associated injection time. Values from statistical probability distribution of the process parameters were employed to find the solution space for this engineering application through deterministic physics-based process flow modeling simulations. A bivariate confidence envelope was developed using the appropriate Cumulative Density Function for a 95% probability of successfully completing resin infusion prior to physical resin gelation time. A logistic regression model for the influence of resin viscosity and permeability on the binary response of successful resin infusion is presented and conforms well to the sensitivity analysis inferences.