CN108995240B - Forming method of composite material cylindrical component - Google Patents
Forming method of composite material cylindrical component Download PDFInfo
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- CN108995240B CN108995240B CN201810634589.9A CN201810634589A CN108995240B CN 108995240 B CN108995240 B CN 108995240B CN 201810634589 A CN201810634589 A CN 201810634589A CN 108995240 B CN108995240 B CN 108995240B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
Abstract
The invention relates to a method for forming a composite material cylindrical component, and belongs to the technical field of composite material preparation processes. According to the invention, positive pressure is applied in the automatic laying process of the non-90-degree layer to form forming pressure. The tape laying forming pressure and the winding tension are converted into the forming pressure, the coordination control is carried out according to the provided forming pressure, the winding tension and the tape laying pressure are adjusted according to the requirements of the width of the actual prepreg tape, the total thickness of the laid layer, the diameter of a product and the like, the aim of basically consistent forming pressure is achieved, and the matching of the tape laying and winding processes is realized.
Description
Technical Field
The invention relates to a method for forming a composite material cylindrical component, and belongs to the technical field of composite material preparation processes.
Background
The existing composite material cylindrical structure mainly has three molding processes, one is a manual prepreg laying molding process, and the other is a fiber winding molding process. The other is a tape laying forming process. The manual prepreg laying forming process has low laying angle precision, unstable laying quality and lower forming efficiency; the winding range is limited when the cylindrical structure is formed by the fiber winding forming process, and local winding cannot be performed; the forming angle of the fiber winding forming process is limited, and small-angle winding cannot be carried out; the fiber winding forming process needs to be wound with a sealing head, so that fiber waste exists; the prepreg loss rate is high when the tape laying forming process forms a large-angle (more than 60 degrees) layer, and the efficiency is low when a 90-degree annular layer is formed.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the method has the advantages of high forming angle precision, stable forming quality, low raw material loss rate and high forming efficiency, and can be used for locally reinforcing any position of the cylindrical structure.
The technical solution of the invention is as follows:
a method of forming a composite tubular member, the method comprising the steps of:
(1) manufacturing a molding male die of the composite material cylindrical component;
(2) cutting the prepreg into pieces with the width d1And a width d2Paving the belt;
wherein d is12 pi rcot alpha, r is the outer diameter of the forming male die, alpha is the winding angle, and alpha is preferably 89.0-89.7 degrees;
d22 pi r beta/360, the central angle of the beta-tape, beta preferably 10-15 °;
(3) the width d obtained in the step (2) is adopted2The tape is laid on the surface of the forming male die manufactured in the step (1) (the laying angle is preferably 0-60 degrees), the process is defined as finishing one non-90-degree layer forming (laying forming), and the width d obtained in the step (2) is adopted on the surface of the tape after the p non-90-degree layer forming are finished1Winding the winding belt, and defining the process as finishing one 90-degree layer forming (winding forming) and finishing q 90-degree layer forming; p is 1, 2 or 3, q is 1, 2 or 3; the total thickness of the p layers which are not 90 degrees is not more than 0.6mm, and the total thickness of the q layers which are 90 degrees is not more than 0.6 mm;
the step can also be:
the width d obtained in the step (2) is adopted1The tape is wound on the surface of the forming male die manufactured in the step (1), the process is defined as finishing forming of one 90-degree layer (winding forming), and after finishing forming of q 90-degree layers, the width d obtained in the step (2) is adopted on the surface of a winding layer2The paving belt is paved (the paving angle is preferably 0-60 degrees), and the process is defined as finishing the molding of a non-90-degree layer (paving molding) and finishing the molding of p 90-degree layers; p is 1, 2 or 3, q is 1, 2 or 3; p non-90 degree layer forming assemblyThe thickness is not more than 0.6mm, and the total thickness of the formed q 90-degree layers is not more than 0.6 mm;
(4) repeating the step (3), namely alternately performing non-90-degree layer forming and 90-degree layer forming until the number of forming layers is a set value n and the total thickness of the fibers is a set value tf；
(5) And (5) curing and molding the product obtained in the step (4), and demolding to obtain the composite material cylindrical member.
The method for determining the winding tension when performing 90-degree layer forming, namely winding forming, comprises the following steps:
wherein, T (T)γ): winding thickness tγThe tension of the winding is measured;
tγ: first, theγThe total thickness of the fiber after the layer winding is finished;
K＝σ0(tf+tMf)，tfis the total thickness of the fiber; sigma0Is the initial tension value of the fiber;
tMfconverting the thickness of the forming male die into the equivalent thickness of the fiber;
EMto shape the modulus of elasticity of the male mould, EfIs the modulus of elasticity, t, of the fiberMTo the thickness (wall thickness) of the forming punch;
the method for determining the laying pressure during non-90-degree layer forming, namely laying forming, comprises the following steps:
in the formula: f is positive pressure; k is a process coefficient, suggestsThe value is 0.5 to 3; d2The width of the tape is the width of the tape, namely the width of the prepreg of the non-90-degree layer; h is the contact width of the press roller; t (T)γ) For winding tension, RγIs as followsγThe sum of the total thickness of the formed fibers and the outer diameter of the forming male die during layer laying.
The method comprises the steps of firstly manufacturing a forming male die, then slitting the prepreg, and slitting the prepreg into the width required by broadband winding and automatic laying according to the outer diameter of the formed cylindrical component. When the prepreg is cut, the width of the prepreg wound by the wide belt is recommended to enable the winding angle to be 89.0-89.7 degrees, and the corresponding central angle of the prepreg width of the automatic tape laying is smaller than 15 degrees when the prepreg is laid. And finally, forming the cylindrical member. The molding of the cylindrical member comprises 90-degree layer molding and non-90-degree layer molding, and the 90-degree layer molding and the non-90-degree layer molding are alternately molded. The 90 ° layers of the cylindrical member are formed using a wide-band winding technique. Winding tension is required to be applied in the 90-degree layer forming process; the non-90-degree layer is formed by using an automatic tape laying technology, and positive pressure stress is applied in the non-90-degree layer forming process; the 90 degree layer winding tension and the non-90 degree layer forward compression stress need to be matched with each other. And then curing the cylindrical member. According to the resin system of the prepreg, a curing system is established to cure the cylindrical member.
The diameter of the cylindrical member is larger than 800mm, the length of the cylindrical member is larger than 0.5m, and in order to ensure the forming efficiency, the length of the cylindrical member is recommended to be larger than 6 m.
The non-90-degree layers comprise all angle layers from 0 degree to 89 degrees, all non-90-degree layers can be laid at high precision, and the non-90-degree optimal range is 0-60 degrees in order to guarantee forming efficiency and prepreg utilization rate.
The cylindrical member may be reinforced at any position of the member.
The width winding and the automatic layering are alternately carried out, the continuous layering of the layers at the same angle does not exceed 3 layers, and the thickness does not exceed 0.6 mm.
Advantageous effects
(1) The invention can make the fiber of each layer of the composite material from inside to outside present certain gradient change through the design of gradient tension, and finally aims to make the fiber of each layer have the same prestress, thereby exerting the whole bearing capacity of the composite material during working.
(2) According to the invention, positive pressure is applied in the automatic laying process of the non-90-degree layer to form forming pressure. The tape laying forming pressure and the winding tension are converted into the forming pressure, the coordination control is carried out according to the provided forming pressure, the winding tension and the tape laying pressure are adjusted according to the requirements of the width of the actual prepreg tape, the total thickness of the laid layer, the diameter of a product and the like, the aim of basically consistent forming pressure is achieved, and the matching of the tape laying and winding processes is realized.
(3) The molding test of the cylindrical member molded by the method provided by the invention proves that the molding pressure matching mode is reasonable and feasible, the layering compactness of the large-thickness side wall of the composite cylinder is ensured, and the molding quality is improved. Therefore, the process method has great advantages in forming speed and forming quality for forming the large-thickness large-size composite material cylindrical member.
(4) The tape laying efficiency of the invention reaches 27kg/h, the broadband winding efficiency reaches 45kg/h, and the tape laying angle precision is improved to +/-0.2 degrees from +/-2 degrees of manual laying.
(5) The method of the invention prepares prepreg first and prepares a forming male die. The molding of the composite cylindrical component comprises 90-degree layer molding and non-90-degree layer molding, the prepreg is cut into required widths for standby, the cutting width of the prepreg is determined according to the radius of the cylindrical component, the 90-degree layer prepreg width is recommended to enable the winding angle to be 89.0-89.7 degrees, and the corresponding central angle is smaller than 15 degrees when the non-90-degree layer prepreg is laid. In the forming process of the cylindrical member, automatic tape laying forming is adopted on a non-90-degree layer, annular broadband winding forming is adopted on a 90-degree layer, and automatic tape laying and broadband winding are alternately carried out. And curing the cylindrical member after all the layers are formed.
(6) The invention describes an automatic forming process method suitable for a composite material cylindrical component, and belongs to the technical field of composite material preparation processes. The process method carries out matching optimization on the automatic tape laying technology and the broadband winding technology in the forming process of the composite cylindrical member, is applied to the development and production of the cylindrical member, improves the layering angle precision, the compactness and the forming efficiency of the composite cylindrical member, and shortens the forming period of the member by nearly half.
Drawings
FIG. 1 is a schematic flow chart of the method of the present invention.
Detailed Description
The process flow for forming the composite material cylindrical member is shown in fig. 1. The prepreg is prepared first and a male mold is prepared for molding. The molding of the composite cylindrical component comprises 90-degree layer molding and non-90-degree layer molding, the prepreg is cut into required widths for standby, the cutting width of the prepreg is determined according to the radius of the cylindrical component, the 90-degree layer prepreg width is recommended to enable the winding angle to be 89.0-89.7 degrees, and the corresponding central angle is smaller than 15 degrees when the non-90-degree layer prepreg is laid. In the forming process of the cylindrical member, automatic tape laying forming is adopted on a non-90-degree layer, annular broadband winding forming is adopted on a 90-degree layer, and automatic tape laying and broadband winding are alternately carried out. And curing the cylindrical member after all layers are molded, and specifically comprising the following implementation steps:
(1) and manufacturing a forming male die.
(2) And (6) cutting the prepreg. And (3) cutting the prepreg into the width required by broadband winding and automatic laying according to the radius of the formed cylindrical component, wherein when the prepreg is cut, the width of the prepreg wound by the broadband is recommended to enable the winding angle to be 89.0-89.7 degrees, and the corresponding central angle of the prepreg width of the automatic laying tape is smaller than 15 degrees when the prepreg is laid.
(3) The cylindrical member is molded. The non-90-degree layers of the cylindrical component are formed by automatic tape laying, the 90-degree layers are formed by circumferential broadband winding, and the automatic tape laying and the broadband winding are alternately carried out.
In order to realize the composite molding of tape laying and winding, the problem of process matching of the two processes needs to be solved, and the matching comprises material matching and process parameter matching. In order to avoid the matching problem caused by materials, the barrel-shaped component formed by compounding adopts the same material, namely, prepreg systems adopted by winding forming and tape laying forming are the same. The process parameter matching mainly comprises the forming temperature and the forming pressure. The molding temperature is matched because the material systems are the same, so the two systems are basically the same, and the room temperature can be controlled. The forming pressure matching is realized by applying hoop winding tension and tape laying positive pressure.
The winding tension is applied in the winding process of the circumferential width of 90 degrees, the winding tension adopts a gradient decreasing tension control system, and the design principle is as follows:
the composite material layer is divided into n layers, and the winding tension from the first layer to the outermost layer is T1, T2 and … … Tn in sequence. The actual stress of each layer of fiber is the sum of the tensile stress generated by each layer of winding tension on the fiber and the compressive stress generated by all outer layer of winding tension on the fiber, and the actual stress is obtained by formula derivation, so that the tension state is uniform after the fiber is wound and formed, and the application formula of each layer of tension is as follows:
in the formula: k ═ σ0(tf+tMf)；
In the formula: t (T)γ): winding thickness tγThe tension of the winding is measured;
tγ: first, theγThe total thickness of the fiber after the layer winding is finished;
tf: total fiber thickness (including non-90 ° layers);
σ0: initial tension value of fiber
tMf: the thickness of the metal die is converted into the equivalent thickness of fiber.
Through the design of gradient tension, the fibers of each layer of the composite material from inside to outside can be in certain gradient change, and the final purpose is to enable the fibers of each layer to have the same prestress, so that the whole bearing capacity of the composite material is exerted during working.
And applying positive pressure in the automatic laying process of the non-90-degree layer to form forming pressure. The tape laying forming pressure and the winding tension are converted into the forming pressure, the coordination control is carried out according to the provided forming pressure, the winding tension and the tape laying pressure are adjusted according to the requirements of the width of the actual prepreg tape, the total thickness of the laid layer, the diameter of a product and the like, the aim of basically consistent forming pressure is achieved, and the matching of the tape laying and winding processes is realized. The non-90 ° pressure calculation method is:
non-90 degree layer forward pressure
In the formula: f is positive pressure; k is a process coefficient, and the suggested value is 0.5-3; d2The tape width is laid for a non-90 degree ply prepreg; h is the contact width of the press roller; t (T)r) At 90 degree layer tension, RλIs the sum of the total thickness of the formed fibers when the gamma layer is laid and the outer diameter of the forming male die.
The cylindrical member forming test verifies that the forming pressure matching mode is reasonable and feasible, the layering compactness of the large-thickness side wall of the composite cylinder is ensured, and the forming quality is improved. Therefore, the process method has great advantages in forming speed and forming quality for forming the large-thickness large-size composite material cylindrical member.
Aiming at the automatic forming technology related to the project, the technology of annular broadband winding technology, automatic tape laying technology of a cylindrical structure and the like are broken through respectively, then the integration of the broadband winding technology and the automatic tape laying technology is completed aiming at the cylindrical structure products, the automatic forming technology of the composite material cylindrical structure is solved, the automatic tape laying efficiency reaches 27kg/h, the broadband winding efficiency reaches 45kg/h, and the angle precision of automatic tape laying and layer laying is improved to +/-0.2 degrees from +/-2 degrees of manual layer laying.
(4) The cylindrical member is cured. According to the resin system of the prepreg, a curing system is established to cure the cylindrical member.
Examples
A cylindrical component with the length of 7m, the radius of 2m and the thickness of 18mm is formed by using the forming process, and the layering sequence of the first 5 layers of the cylindrical structure is [90/0/90/0/90 ]]. The 90-degree layer uses a winding forming mode and the width d of a winding belt150mm, the actual winding angle is 89.5 degrees, 0 degree, the tape laying forming mode is used, and the width d of the tape laying2150mm, 90 ° winding tension 9.2N/mm, 9N/mm, 8.8N/mm, 0 ° ply pressure 19.8N and 19.4N. The molding cycle of the cylindrical member is 12 days, which is shortened by 23 days compared with the original manual molding cycleApproximately half way down.
And (3) detecting the whole formed cylindrical member by using an ultrasonic nondestructive detection method, wherein the detection result shows that the whole member has no defects of layering, looseness, air holes and the like, locally sampling the member to prepare a metallographic test, and metallographic observation shows that the porosity of the member is lower than 0.3%.
Claims (1)
1. A method of forming a composite tubular member, the method comprising:
preparing prepreg, preparing a molding male die, molding a composite material cylindrical component, wherein the molding of the composite material cylindrical component comprises 90-degree layer molding and non-90-degree layer molding, cutting the prepreg into required widths for standby, the cutting width of the prepreg is determined according to the radius of the cylindrical component, the winding angle of the 90-degree layer prepreg is 89.0-89.7 degrees, the corresponding central angle of the non-90-degree layer prepreg during laying is less than 15 degrees, the non-90-degree layer is molded by automatic tape laying in the molding process of the cylindrical component, the 90-degree layer is molded by circumferential broadband winding, the automatic tape laying and the broadband winding are alternately performed, the cylindrical component is cured after the molding of all the layers is completed, and the specific implementation steps are as:
(1) manufacturing a forming male die;
(2) cutting the prepreg into the width required by the broadband winding and automatic laying according to the radius of the formed cylindrical component, wherein when the prepreg is cut, the winding angle of the prepreg wound by the broadband is 89.0-89.7 degrees, and the corresponding central angle of the prepreg width of the automatic laying belt is less than 15 degrees when the prepreg is laid;
(3) forming a cylindrical component, wherein non-90-degree layers of the cylindrical component are formed by adopting automatic tape laying, 90-degree layers are formed by adopting annular broadband winding, and automatic tape laying and broadband winding are alternately carried out;
the prepreg system adopted for winding molding and tape laying molding is the same;
applying winding tension in the winding process of the circumferential width of the 90-degree layer, wherein the winding tension adopts a gradient decreasing tension control system;
dividing the composite material layer into n layers, wherein the winding tension from the first layer to the outermost layer is T1, T2 and … … Tn in sequence, the actual stress of each layer of fiber is the sum of the tensile stress generated by each layer of winding tension to the fiber and the compressive stress generated by all the outer layer of winding tension to the fiber, and the application formula of each layer of tension is as follows:
in the formula: k ═ σ0(tf+tMf)；
In the formula: t (T)γ): winding thickness tγThe tension of the winding is measured;
tγ: first, theγTotal thickness of fiber after layer winding
tf: total thickness of fibres, including non-90 DEG layers
σ0: initial tension value of fiber
tMf: converting the thickness of the metal die into the equivalent thickness of the fiber
Applying positive pressure in the automatic laying process of the non-90-degree layer to form forming pressure, converting tape laying forming pressure and winding tension into forming pressure, carrying out coordination control according to the provided forming pressure, combining the requirements of the width, the total laying thickness and the product diameter of the actual prepreg tape, adjusting the winding tension and the tape laying pressure to achieve the aim of consistent forming pressure, realizing matching of tape laying and winding processes, wherein the non-90-degree pressure calculation method comprises the following steps:
non-90 degree layer forward pressure
In the formula: f is positive pressure; k is a process coefficient, and the suggested value is 0.5-3; d2The tape width is laid for a non-90 degree ply prepreg; h is the contact width of the press roller; t (T)r) At 90 degree layer tension, RλThe sum of the total thickness of the formed fibers and the outer diameter of the forming male die when the gamma layer is laid;
the automatic tape laying efficiency reaches 27kg/h, the broadband winding efficiency reaches 45kg/h, and the angle precision of the automatic tape laying layer is improved to +/-0.2 degrees from +/-2 degrees of manual layer laying;
(4) curing the cylindrical member, wherein a curing system is established according to a resin system of the prepreg, the cylindrical member is cured, after the curing is finished, a cylindrical member with the length of 7m, the radius of 2m and the thickness of 18mm is obtained, and the layering sequence of the front 5 layers of the cylindrical member is [90/0/90/0/90 ]]90 degree layer using winding forming method, width d of winding belt150mm, the actual winding angle is 89.5 degrees, 0 degree, the tape laying forming mode is used, and the width d of the tape laying2150mm, the 90-degree winding tension is 9.2N/mm, 9N/mm and 8.8N/mm, the pressure of 0-degree layering is 19.8N and 19.4N, the molding cycle of the cylindrical member is 12 days, and is shortened by nearly half compared with the original manual molding cycle of 23 days;
and detecting the whole formed cylindrical member by using an ultrasonic nondestructive detection method, wherein the detection result shows that the member has no layering, loosening and pore defects, the member is locally sampled to be prepared into a metallographic test, and metallographic observation shows that the porosity of the member is lower than 0.3%.
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| CN111331877B (en) * | 2020-02-17 | 2022-05-17 | 浙江理工大学 | Preparation method of variable-stiffness composite material spiral spring |
| CN115557743B (en) * | 2022-11-04 | 2023-07-18 | 江苏宇航板业有限公司 | Production method of single-blank calcium silicate cement board |
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| US4588538A (en) * | 1984-03-15 | 1986-05-13 | Celanese Corporation | Process for preparing tapes from thermoplastic polymers and carbon fibers |
| WO1989003761A1 (en) * | 1987-10-16 | 1989-05-05 | Loctite Corporation | Fiber/resin composites, and method of making the same |
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|---|---|---|---|---|
| US4459171A (en) * | 1981-09-28 | 1984-07-10 | The Boeing Company | Mandrel for forming a composite panel of varied thickness |
| US5261616A (en) * | 1992-02-19 | 1993-11-16 | The United States Of America As Represented By The Secretary Of The Navy | Multi-layered translated rib-stiffened composite hollow cylinder assembly |
| CN1261292C (en) * | 2003-09-30 | 2006-06-28 | 中材科技股份有限公司 | Filament winding composite material pressure vessel gradient tension construction method |
| CN103538263B (en) * | 2013-11-07 | 2015-08-19 | 哈尔滨工业大学 | A kind of preparation method of carbon fibre composite motor retaining ring |
| CN103722787B (en) * | 2013-12-04 | 2016-01-13 | 航天材料及工艺研究所 | A kind of Cylinder shape constructional element laying/winding integrated molding device |
| CN103978698B (en) * | 2014-05-21 | 2016-03-30 | 航天材料及工艺研究所 | A kind of composite material taper housing forming method of band edge frame |
| CN105690795B (en) * | 2016-03-21 | 2018-04-10 | 航天材料及工艺研究所 | A kind of semi-enclosed cavity grid stressed-skin construction composite material shaping mould and method |
| CN106956472B (en) * | 2017-03-03 | 2019-10-22 | 航天材料及工艺研究所 | A kind of composite material shock resistance structure and its forming method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4588538A (en) * | 1984-03-15 | 1986-05-13 | Celanese Corporation | Process for preparing tapes from thermoplastic polymers and carbon fibers |
| WO1989003761A1 (en) * | 1987-10-16 | 1989-05-05 | Loctite Corporation | Fiber/resin composites, and method of making the same |
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