Finite element solution of electro-magnetic-thermo-chemical problem in microwave assisted pultrusion processes

New finite element models and algorithms are developed for a solution of coupled electro-magnetic-thermo-chemical problem arising in microwave assisted pultrusion processes. In the first algorithm stage, the microwave set-up is predefined according to the requirements on energy-effectiveness and homogeneity of generated absorption field, in the second – an iterative procedure preserving the dependence of dielectric material properties on microwave frequency, temperature and degree of cure is applied to avoid resin overheating and flow from the die exit, and to guarantee a required profile quality. These holistic simulation tools are built by using the general-purpose finite element software ANSYS that makes available various modelling and analysis features of the finite element package and results in considerable savings in design time and costs. To demonstrate features and benefits of electromagnetic heating, the pultrusion process for a production of the rod profile with diameter of 16 mm and made of polyester resin POLRES 305 BV and glass fibers 4800 tex is developed. Based on the results of parametric study executed for the microwave assisted pultrusion set-ups with different ceramic dies, finite element modelling and coupled analysis aspects are discussed.