Intugent I-Rheo

Process Simulation Software for Thermoset Polymers

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Increase your odds of being successful at the very first commercial scale application of thermoset polymer systems by simulating the process with I-Rheo. Use I-Rheo to reduce developmental times and costs. Designed by researchers with extensive experience in thermoset polymers and composites, it is based on the latest developments in the materials science of thermoset polymers. A searchable database allows researchers to share the kinetic and rheology models and simulate commercial application processes. I-Rheo’s intuitive front-end and powerful optimization engine makes it easy for everyone to use it. Technical sales staff can use I-Rheo to identify systems with right mechanical properties and processing characteristics. No background in mathematical modeling is needed. Key features of the software are described below.

Process Simulation - Pultrusion

Obtain a deeper understanding of the pultrusion process using I-Rheo's pultrusion module. With standard shapes already built in the library, engineers only need to specify the die temperatures, size of the part, type of fibers and commonly available resin and fiber properties. No need to have any background in Math Modeling and Finite Element Analysis. Our state-of-the-art computational engine simultaneously solves reaction kinetics, rheology, and heat transfer equations in a matter of seconds.

Engineers can use these simulations to optimize the process for the right pot life, minimum viscosity during the application, gel time, and exotherm position. In the pultrusion application, if the minimum viscosity is too low, resin may flow back to the resin bath. On the other hand, if the minimum viscosity is too high, the filaments will not wet properly and the composite will have poor properties. If the maximum temperature at the center of the part takes place outside the die, the thermal stresses may result in cracks and the poor surface quality.

Engineers can also compare the performance of up to five different thermoset systems selected from the database. It is recommended to choose as a reference at least one thermoset system whose performance in the process is well known.

Process Simulation with Given Time-Temperature Profile

In many application processes such as filament winding, adhesives, coatings, sealants, and elastomers, time-temperature profiles through the application process are fairly well known. With I-Rheo, engineers can simulate progress of reactions and viscosity development using the time-temperature profile of the application process. They can optimize the process for the right pot life, minimum viscosity during the application, gel time, green strength time and other processing parameters.

The minimum viscosity that a thermoset system achieves during the process is usually an important parameter. For example, in filament winding, if the minimum viscosity is too low, resin may squeeze out during curing. On the other hand, if the minimum viscosity is too high, the filaments will not wet properly and the composite will have poor properties.

Engineers can also compare the performance of up to five different thermoset systems selected from the database. It is recommended to choose as a reference at least one thermoset system whose performance in the process is well known.

Development of Rheo-Kinetic Model for Process Simulation

With I-Rheo, engineers can develop rheo-kinetic model for a new formulation without any help from math modeling subject matter experts. Use 2-5 DSC scans (isothermal or dynamic) to develop a kinetic model for the given thermoset system. The choice of models available can take into account autocatalytic reactions, gelation and vitrification, step growth polymers as well chain growth polymers. I-Rheo auto-detects reaction peaks and draws the baseline. Users can graphically change the end points of reaction exotherm and type of baseline, if needed.

Development of rheology model requires 1-3 rheology scans and a kinetic model for the thermoset system. A variety of rheology models are available that can take into account gelation and vitrification.

Engineers can develop kinetic and rheology models with a click of button and graphically view quality of predictions. After a model has been developed, it can be saved into the database for industrial process simulations.