CN109016697A - 一种泡沫-波纹复合点阵金属夹芯圆锥壳及制备方法 - Google Patents
一种泡沫-波纹复合点阵金属夹芯圆锥壳及制备方法 Download PDFInfo
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Abstract
一种泡沫‑波纹复合点阵金属夹芯圆锥壳及制备方法，泡沫‑波纹复合点阵金属夹芯圆锥壳包括波纹芯体，波纹芯体为圆锥形金属波纹结构，设置在内圆锥壳和外圆锥壳之间，在波纹芯体、内圆锥壳和外圆锥壳之间孔隙中设置有泡沫填充材料；制备方法是先通过圆锥形波纹模具制备波纹芯体；再制备内圆锥壳和外圆锥壳；将波纹芯体和内圆锥壳、外圆锥壳装配，得到波纹点阵金属夹芯圆锥壳；将泡沫条与波纹点阵金属夹芯圆锥壳进行拼装，得到泡沫‑波纹复合点阵金属夹芯圆锥壳；本发明将泡沫‑波纹复合点阵芯体与夹芯圆锥壳结构结合在一起，缓冲吸收更多的冲击能量。
Description
技术领域
本发明属于夹芯圆锥壳技术领域，特别涉及一种泡沫-波纹复合点阵金属夹芯圆锥壳及制备方法。
背景技术
薄壁圆锥壳，因其高比吸能、高容积效率以及良好的空气动力学特性等优势，广泛应用于化工、航空航天、交通运输及核能设备等诸多民用和国防重要工业领域。相较于圆柱壳，薄壁圆锥壳的轴压特新体现出更为平稳的载荷-位移响应，较低的冲击载荷(峰值载荷)，更稳定有效的压溃耗能变形机制(抑制整体Euler屈曲失稳的发生)，因而体现出更优越的轴压吸能特性。然而，轴向冲击下薄壁金属圆锥壳的能量耗散通常集中在结构的一个相对狭窄区域，其余部分只发生刚性运动，导致材料塑性变形利用率较低、吸能效率有限。面向航天航空领域，例如深空探测星球软着陆技术，要求着陆器碰撞防护的缓冲装置具有质量小、较高吸能效率、可缓冲较大冲击载荷等诸多特点。针对这一应用背景，设计并制备新型薄壁圆锥壳结构，实现高效缓冲吸能，具有重要现实意义。
近年来，点阵多孔材料以其轻质、高强和耐冲击等优良的结构性能和吸声降噪、高效散热及智能化等多功能特性，成为众多学者和工程技术人员关注的热点。与单层圆锥壳相比，以点阵多孔材料为芯体的夹芯壳有望实现小质量下更高的缓冲吸能效率。
目前还没有将点阵多孔材料用于薄壁圆锥壳的文献公开。
发明内容
为了克服上述现有技术的缺点，本发明的目的在于提供一种泡沫-波纹复合点阵金属夹芯圆锥壳及制备方法，将泡沫-波纹复合点阵芯体与夹芯圆锥壳结构结合在一起，缓冲吸收更多的冲击能量。
为了达到上述目的，本发明采取的技术方案为：
一种泡沫-波纹复合点阵金属夹芯圆锥壳，包括内圆锥壳1、外圆锥壳2、波纹芯体3和泡沫填充材料4，波纹芯体3为圆锥形金属波纹结构，设置在内圆锥壳1和外圆锥壳2之间，在波纹芯体3、内圆锥壳1和外圆锥壳2之间孔隙中设置有泡沫填充材料4，内圆锥壳1、外圆锥壳2、波纹芯体3与泡沫填充材料4连接构成泡沫-波纹复合点阵金属夹芯圆锥壳。
所述波纹芯体3中的波纹单胞，沿环向几何形状相同，且均匀分布，沿轴向有锥度和梯度变化。
所述波纹芯体3的波纹斜板与圆锥壳环向切线夹角为30～60°。
所述内圆锥壳1、外圆锥壳2、波纹芯体3和泡沫芯材料4的锥度相同。
所述波纹芯体3、内圆锥壳2和外圆锥壳1采用铝合金、钛合金或不锈钢制成；泡沫填充材料4是泡沫铝或PMI泡沫。
所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，包括以下步骤：
S1、用线切割机/激光切割机将平整处理后的金属板材切割成扇形平板，然后采用模压折弯技术制成具有梯形平台的金属波纹板；
S2、将步骤S1制备的金属波纹板清洗去除油污和锈迹后，在圆锥形波纹模具上固型，圆锥形波纹模具包括波纹状模具5、钢制棱柱压条6、上压模8和下压模9，通过波纹状磨具5和钢制棱柱压条6将金属波纹板固定在两者之间，通过加盖上压模8和下压模9，并紧固螺栓7施加预压力，实现圆锥形波纹芯体的固型；最后拆卸螺栓7，脱模得到圆锥形波纹芯体3；
S3、将平整过的金属板材切割为扇形，通过表面处理去除油污和锈迹，以金属圆锥壳为模具，在其上覆盖金属板材并连接成一体，脱模分别制成内圆锥壳1和外圆锥壳2；
S4、对步骤S2制备的波纹芯体3和步骤S3制备的内圆锥壳1、外圆锥壳2进行表面处理，去除油污和锈迹后进行装配，得到波纹点阵金属夹芯圆锥壳；
S5、采用线切割技术/热电阻丝线切割技术将块状泡沫铝/PMI泡沫切割成与波纹芯体的孔隙相匹配的具有锥度的泡沫条，与步骤S4的波纹点阵金属夹芯圆锥壳进行拼装，得到泡沫-波纹复合点阵金属夹芯圆锥壳。
所述波纹芯体3、内圆锥壳1和外圆锥壳2采用胶接或焊接方式连接。
所述胶接采用环氧树脂胶作为胶结剂，所述焊接采用真空钎焊方式，真空度为10-2～10-3Pa，以1℃/min速度自室温升温至900℃保温10min～1h后冷却至室温。
所述泡沫条与波纹点阵夹芯圆锥壳采用胶接方式连接。
与现有技术相比，本发明具有以下有益效果：
本发明一种泡沫-波纹复合点阵金属夹芯圆锥壳，波纹芯体中的波纹单胞几何形状相同，沿环向均匀分布，经有限元仿真分析发现，波纹点阵金属夹芯圆锥壳在轴向压缩下，波纹点阵金属夹芯圆锥壳相较于各独立组件具有明显的耦合增强效应，具有更高能量吸收效率和优异的缓冲吸能特性，工艺成熟，便于批量生产，具有广阔的市场前景；其制备方法过程简单，工艺成熟，可进行批量生产。
泡沫-波纹复合点阵金属夹芯圆锥壳相较于波纹点阵金属夹芯圆锥壳和独立的泡沫芯体，泡沫和金属壳之间具有明显的耦合增强效应，能量吸收效率提高近50％，在缓冲吸能方面具有明显优势。
附图说明
图1为本发明的泡沫-波纹复合点阵金属夹芯圆锥壳。
图2为本发明的圆锥形波纹芯体模具。
图3为本发明PMI泡沫-波纹复合点阵金属夹芯圆锥壳及其各独立组件轴向压缩下的载荷-位移曲线。
具体实施方式
下面结合附图及实施例对本发明作进一步详细说明。
参照图1，一种泡沫-波纹复合点阵金属夹芯圆锥壳，包括内圆锥壳1、外圆锥壳2、波纹芯体3和泡沫填充材料4，波纹芯体3为圆锥形金属波纹结构，设置在内圆锥壳1和外圆锥壳2之间，在波纹芯体3、内圆锥壳1和外圆锥壳2之间孔隙中设置有泡沫填充材料4，内圆锥壳1、外圆锥壳2、波纹芯体3与泡沫填充材料4连接构成泡沫-波纹复合点阵金属夹芯圆锥壳。
所述波纹芯体3中的波纹单胞，沿环向几何形状相同，且均匀分布，沿轴向有锥度和梯度变化。
所述波纹芯体3的波纹斜板与圆锥壳环向切线夹角为30～60°。
所述内圆锥壳1、外圆锥壳2、波纹芯体3和泡沫芯材料4的锥度相同。
所述波纹芯体3、内圆锥壳2和外圆锥壳1采用铝合金、钛合金或不锈钢制成；泡沫填充材料4是泡沫铝或PMI泡沫。
所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，包括以下步骤：
S1、用线切割机/激光切割机将平整处理后的金属板材切割成扇形平板，然后采用模压折弯技术制成具有梯形平台的金属波纹板；
S2、将步骤S1制备的扇形金属波纹板清洗去除油污和锈迹后，在圆锥形波纹模具上固型；参照图2，圆锥形波纹模具包括波纹状模具5、钢制棱柱压条6、上压模8和下压模9，通过波纹状磨具5和钢制棱柱压条6将金属波纹板固定在两者之间，通过加盖上压模8和下压模9，并紧固螺栓7施加预压力，实现圆锥形波纹芯体的固型；最后拆卸螺栓7，脱模得到圆锥形波纹芯体3；
S3、将平整过的金属板材切割为扇形，通过表面处理去除油污和锈迹，以金属圆锥壳为模具，在其上覆盖金属板材并连接成一体，脱模分别制成内圆锥壳1和外圆锥壳2；
S4、对步骤S2制备的波纹芯体3和步骤S3制备的内圆锥壳1、外圆锥壳2进行表面处理，去除油污和锈迹后进行装配，得到波纹点阵金属夹芯圆锥壳；
S5、采用线切割技术/热电阻丝线切割技术将块状泡沫铝/PMI泡沫切割成与波纹芯体的孔隙相匹配的具有锥度的泡沫条，与步骤S4的波纹点阵金属夹芯圆锥壳进行拼装，得到泡沫-波纹复合点阵金属夹芯圆锥壳。
所述波纹芯体3、内圆锥壳1和外圆锥壳2采用胶接或焊接方式连接；当波纹芯体3以及内圆锥壳1、外圆锥壳2较薄时，波纹芯体3与内圆锥壳1、外圆锥壳2之间采用环氧树脂胶粘接处理，其界面连接强度高，固化时间短，易于加工，同时胶水固化收缩率小，内应力小；当波纹芯体3以及内圆锥壳1、外圆锥壳2较厚时，波纹芯体3与内圆锥壳1、外圆锥壳2之间使用真空钎焊连接强度高，焊件变形小，可是同焊接多条钎缝，生产效率高。
所述胶接采用环氧树脂胶作为胶结剂，所述焊接采用真空钎焊方式，真空度为10-2～10-3Pa，以1℃/min速度自室温升温至900℃保温10min～1h后冷却至室温。
所述泡沫条与波纹点阵夹芯圆锥壳采用胶接方式连接。
经有限元仿真分析发现，波纹点阵金属夹芯圆锥壳在轴向压缩下，波纹点阵金属夹芯圆锥壳相较于各独立组件具有明显的耦合增强效应。相较于波纹点阵金属夹芯圆锥壳和独立的泡沫芯体，泡沫-波纹复合点阵金属夹芯圆锥壳的泡沫组件和金属壳之间具有明显的耦合增强效应，能量吸收效率提高近50％，在缓冲吸能方面都具有明显优势。
参照图3，图3为PMI泡沫-波纹复合点阵金属夹芯圆锥壳及其各独立组件轴向压缩下的位移载荷曲线，黑色带五角星的实线为泡沫-波纹复合点阵金属夹芯圆锥壳轴向压缩下的载荷位移曲线，黑色带三角形的实线为波纹点阵金属夹芯圆锥壳和独立的等质量等高度泡沫柱体在轴向压缩的载荷位移曲线之和，阴影部分表示波纹点阵金属夹芯圆锥壳和独立的泡沫芯体在轴向压缩下的耦合增强效应。
以上内容仅为说明本发明的技术思想，不能以此限定本发明的保护范围，凡是按照本发明提出的技术思想，在技术方案基础上所做的任何改动，均落入本发明权利要求书的保护范围之内。以上内容仅为说明本发明的技术思想，不能以此限定本发明的保护范围，凡是按照本发明提出的技术思想，在技术方案基础上所做的任何改动，均落入本发明权利要求书的保护范围之内。
Claims (9)
1.一种泡沫-波纹复合点阵金属夹芯圆锥壳，包括内圆锥壳(1)、外圆锥壳(2)、波纹芯体(3)和泡沫填充材料(4)，其特征在于：波纹芯体(3)为圆锥形金属波纹结构，设置在内圆锥壳(1)和外圆锥壳(2)之间，在波纹芯体(3)、内圆锥壳(1)和外圆锥壳(2)之间孔隙中设置有泡沫填充材料(4)，内圆锥壳(1)、外圆锥壳(2)、波纹芯体(3)与泡沫填充材料(4)连接构成泡沫-波纹复合点阵金属夹芯圆锥壳。
2.根据权利要求1所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳，其特征在于：所述波纹芯体(3)中的波纹单胞，沿环向几何形状相同，且均匀分布，沿轴向有锥度和梯度变化。
3.根据权利要求1所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳，其特征在于：所述波纹芯体(3)的波纹斜板与圆锥壳环向切线夹角为30～60°。
4.根据权利要求1所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳，其特征在于：所述内圆锥壳(1)、外圆锥壳(2)、波纹芯体(3)和泡沫芯材料(4)的锥度相同。
5.根据权利要求1所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳，其特征在于：所述波纹芯体(3)、内圆锥壳(2)和外圆锥壳(1)采用铝合金、钛合金或不锈钢制成；泡沫填充材料(4)是泡沫铝或PMI泡沫。
6.根据权利要求1所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，其特征在于，包括以下步骤：
S1、用线切割机/激光切割机将平整处理后的金属板材切割成扇形平板，然后采用模压折弯技术制成具有梯形平台的金属波纹板；
S2、将步骤S1制备的金属波纹板清洗去除油污和锈迹后，在圆锥形波纹模具上固型，圆锥形波纹模具包括波纹状模具(5)、钢制棱柱压条(6)、上压模(8)和下压模(9)，通过波纹状磨具(5)和钢制棱柱压条(6)将金属波纹板固定在两者之间，通过加盖上压模(8)和下压模(9)，并紧固螺栓(7)施加预压力，实现圆锥形波纹芯体的固型；最后拆卸螺栓(7)，脱模得到圆锥形波纹芯体(3)；
S3、将平整过的金属板材切割为扇形，通过表面处理去除油污和锈迹，以金属圆锥壳为模具，在其上覆盖金属板材并连接成一体，脱模分别制成内圆锥壳(1)和外圆锥壳(2)；
S4、对步骤S2制备的波纹芯体(3)和步骤S3制备的内圆锥壳(1)、外圆锥壳(2)进行表面处理，去除油污和锈迹后进行装配，得到波纹点阵金属夹芯圆锥壳；
S5、采用线切割技术/热电阻丝线切割技术将块状泡沫铝/PMI泡沫切割成与波纹芯体的孔隙相匹配的具有锥度的泡沫条，与步骤S4的波纹点阵金属夹芯圆锥壳进行拼装，得到泡沫-波纹复合点阵金属夹芯圆锥壳。
7.根据权利要求6所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，其特征在于：所述波纹芯体(3)、内圆锥壳(1)和外圆锥壳(2)采用胶接或焊接方式连接。
8.根据权利要求7所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，其特征在于：所述胶接采用环氧树脂胶作为胶结剂，所述焊接采用真空钎焊方式，真空度为10-2～10-3Pa，以1℃/min速度自室温升温至900℃保温10min～1h后冷却至室温。
9.根据权利要求6所述的一种泡沫-波纹复合点阵金属夹芯圆锥壳的制备方法，其特征在于：所述泡沫条与波纹点阵夹芯圆锥壳采用胶接方式连接。
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