Achieving stable resin content in CCF/PEEK prepreg tapes remains challenging due to powder settling and concentration stratification in impregnation tanks. This study presents a novel approach that integrates CFD-DEM simulation (Fluent/Rocky) with response surface methodology (RSM) to optimize stirring parameters in wet powder impregnation. Unlike previous studies that focused on downstream consolidation, this work addresses upstream powder suspension uniformity. The effects of rotational speed, blade depth, and blade width on solid content distribution were systematically investigated. A quadratic regression model (R2 = 0.9981) identified the optimal parameters: a rotational speed of 600 r/min, a blade depth of 41 mm, and a blade width of 40 mm. Verification experiments confirmed that resin content remained within 45% ± 3%, and SEM analysis demonstrated uniform fiber impregnation. This CFD-DEM/RSM framework provides a generalizable methodology for optimizing thermoplastic prepreg manufacturing.
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