CN110728085B - Method for simulating composite material deformation caused by workpiece-mould interaction - Google Patents
Method for simulating composite material deformation caused by workpiece-mould interaction Download PDFInfo
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Abstract
The invention relates to a method for simulating composite material deformation caused by workpiece-mould interaction, which is characterized in that a shell unit is built on a finite element model of a workpiece, the shell unit has higher rigidity and can simulate the rigidity and the shape of a forming surface of a mould, and the thermal expansion coefficient of materials adopted by the shell unit is adjusted to simulate the mould-workpiece interaction of different degrees, so that the method does not need to build a complete mould grid model, only needs to build a shell unit model on the film sticking surface of the workpiece to simulate the action of the mould on the workpiece, and greatly reduces the complexity of the finite element model. In the method, the parameters of the shell unit material are determined by the deformation result of the flat plate verification piece which is symmetrically layered, the shape of the verification piece is simple, the verification piece is in a cylindrical shape with a single curved surface after being deformed, the thickness is small, enough deformation is easy to generate, and the deformation amount is easy to measure; the anisotropic thermal expansion characteristic and chemical contraction characteristic of the material are not required to be considered, and the required input material parameters are simple. The method does not relate to the problem of interface contact, so that the introduction of a nonlinear problem is avoided, the calculated amount is small, and the convergence is good.
Description
Technical Field
The invention discloses a method for simulating deformation of a composite material caused by interaction of a workpiece and a mold, and belongs to the technical field of deformation simulation in the forming process of the composite material.
Background
Composite materials have been widely used due to their high specific strength and modulus, but thermosetting resin-based composite material structures have a certain degree of inconsistency between their free shape at room temperature and the desired shape due to the anisotropic thermal expansion and chemical contraction properties of the materials and the interaction between the product and the mold during the molding process, which is called the curing deformation of the composite material structure. The curing deformation of the composite material part with a complex geometric shape is difficult to determine according to experience, the deformation analysis of the composite material part is realized by adopting a numerical simulation technology, and then the deformation control is carried out according to the result, so that the development efficiency can be effectively improved, and the development cost can be reduced.
The simulation of the curing deformation of the composite material part requires the establishment of a finite element model of the composite material part and the determination of material parameters. The anisotropic thermal expansion and chemical contraction characteristics of the material result in relatively simple simulation of deformation, because the testing methods and instruments for the material properties are relatively mature. However, the simulation of deformation caused by the interaction between the product and the mold is difficult. Modeling the interaction between a mold and a composite part generally takes two forms: contact friction or the introduction of shear layers is used.
Deficiencies and improvements in the prior art
The influence factors of the contact friction model on the interaction between the mold and the workpiece are considered comprehensively, and the action mechanism of the factors is also helpful for understanding, but the contact friction is a nonlinear problem, the calculation amount is greatly increased along with the increase of the complexity of the workpiece structure, and the problems of calculation non-convergence and the like may occur. The shear layer is formed by introducing an interface layer between the mould and the composite material, and the thickness and the elastic property of the interface layer are changed to adjust the interaction of the interface. The introduction of the shear layer avoids the nonlinear problem of contact constraint, so the advantages of the shear layer are shown in the aspects of reducing the calculation time, reducing the memory requirement, reducing the material description and the like; however, the parameters of the shear layer have no definite physical meaning, and cannot be measured, and only can be deduced reversely through the deformation result of the workpiece. The contact friction or shear layer method has advantages and disadvantages, and the models of the molds need to be completely built in the modeling of the two methods, so that the workload of modeling is large.
Disclosure of Invention
The invention provides a method for simulating the deformation of a composite material caused by the interaction of a workpiece and a mold, aiming at determining material parameters through simple tests, avoiding the problem of nonlinearity and reducing the complexity of a model.
The purpose of the invention is realized by the following technical scheme:
the simulation method of the composite material deformation caused by the interaction of the part and the mold is characterized in that: the method comprises the following steps:
step one, constructing a finite element model of a part of a composite material part, wherein in the finite element model of the part, a shell unit is adopted to carry out grid division on a film sticking surface of a part entity unit 1, a part mould shell unit 2 is established for simulating the effect of a mould on the composite material part, the part mould shell unit 2 is matched with the part entity unit 1, material parameters of the composite material part adopt material parameters before glass transition after resin is in gel, the part mould shell unit 2 is made of an isotropic material, and the modulus of the isotropic material is far greater than that of a composite material fiber direction so as to ensure that the part mould shell unit 2 has enough rigidity;
step two, constructing a verification piece finite element model of the composite material flat plate verification piece, wherein in the verification piece finite element model, a shell unit is adopted to perform grid division on a film pasting surface of a verification piece entity unit 3, a verification piece mold shell unit 4 is established for simulating the effect of a mold on the composite material flat plate verification piece, the verification piece mold shell unit 4 is matched with the verification piece entity unit 3, the material parameters of the composite material flat plate verification piece adopt the material parameters of the resin before glass transition after gel, the verification piece mold shell unit 4 is made of an isotropic material, and the modulus of the material is far greater than that of the composite material fiber direction so as to ensure that the verification piece mold shell unit 4 has enough rigidity;
step three, preparing the composite material flat plate verification piece by adopting the same forming mode as the composite material part, wherein the die adopts a single-sided die, the composite material and the die material which are the same as the composite material part are adopted, and the thickness of the die can ensure that the die does not deform in the forming process; curing the flat plate verification piece by adopting the same technological parameters as those of the composite material product, and measuring a specific deformation value after demolding after curing;
step four, calculating the deformation of the composite material flat verification piece by using the verification piece finite element model established in the step two, comparing the deformation calculation result and the measurement result of the composite material flat verification piece, if the results are inconsistent, adjusting the thermal expansion coefficient of the material of the verification piece mold shell unit 4 for recalculation until the error of the calculation result compared with the measurement result is less than 5%, wherein the calculation process comprises the following steps:
applying constraint conditions to constrain rigid body displacement on a finite element model of a verification piece;
applying a temperature load from the gel point temperature to the curing temperature on the finite element model of the verification piece to simulate a heating process, submitting calculation and deriving stress from a calculation result;
storing the finite element model of the verification part as a new model, and deleting the die shell unit 4 of the verification part in the new model to only leave the entity unit 3 of the verification part;
applying the derived stress to a verification piece entity unit 3 of a new model, deleting the temperature load and the constraint condition, applying a new constraint condition to the verification piece entity unit 3 again to constrain rigid body displacement, modifying the performance parameters of the composite material into the performance parameters after glass transition, and submitting the parameters to calculation;
and step five, multiplying the thermal expansion coefficient of the material of the verification piece mold shell unit 4 determined in the step four by a coefficient of 0.1-3 to serve as the material parameter of the part finite element model part mold shell unit 2 constructed in the step one, then repeating the calculation process of the step four, replacing the verification piece finite element model with a part finite element model, and finally obtaining a simulation result of the curing deformation of the composite material part caused by the interaction of the part and the mold.
In one implementation, the solid element 1 of the part described in the first step is built by using a pentahedral or hexahedral element based on a geometric model of the composite part.
In one implementation, the matching of the part mold shell unit 2 and the part solid unit 1 in the step one means that the part mold shell unit 2 and the part solid unit 1 share a common node.
In one implementation, the matching of the product mold housing unit 2 and the product solid unit 1 in the step one means that the ratio of the unit characteristic dimension of the film-facing surface of the product solid unit 1 to the thickness of the product mold housing unit 2 is greater than 2. The effect of this technical measure is then to avoid the occurrence of unit malformations.
In one implementation, the verification member entity unit 3 in the step two is established by adopting a pentahedral or hexahedral unit based on a geometric model of the composite verification member.
In one implementation, the verification piece mold shell unit 4 and the verification piece entity unit 3 in the step two are matched, namely, the verification piece mold shell unit 4 and the verification piece entity unit 3 share a node.
In one implementation, the verification piece mold shell unit 4 and the verification piece physical unit 3 in the step two are matched, namely the ratio of the unit characteristic dimension of the film pasting surface of the verification piece physical unit 3 to the thickness of the verification piece mold shell unit 4 is larger than 2.
In one implementation, in the step two, the verifying mold shell unit 4 adopts the same material modulus and thickness as the manufactured part mold shell unit 2, and the verifying part entity unit 3 adopts the same material parameters as the manufactured part entity unit 1;
in one implementation, the entity unit 3 of the certificate inspection unit in the second step adopts symmetrical layering, the thickness is 1 mm-2 mm, and the layering angle is determined based on the layering angle of 1-8 layers of the veneering surface of the entity unit 1 of the workpiece.
In one implementation, the composite material is a fiber reinforced thermosetting resin based composite material; the molding process is that the prepreg is heated and pressurized and cured by adopting a single-sided or double-sided mold, or the resin is injected into the fiber preform and then is vacuumized and heated and cured by adopting the single-sided mold, or the resin is injected into the fiber preform and then is heated and cured by adopting the double-sided closed mold.
The scheme of the invention has the characteristics and beneficial effects that:
(1) A complete die grid model does not need to be established, only a shell unit model needs to be established on the film-sticking surface of the workpiece to simulate the action of the die on the workpiece, and the complexity of the finite element model is greatly reduced.
In the shear layer method, the shear layer only plays a role in transmitting force and displacement, deformation generated by heating the die is transmitted through the shear layer, and die-part interaction with different degrees is simulated by adjusting the shear modulus of the material of the shear layer, so that a finite element model of the die must be completely established; furthermore, the die finite element model serves to provide a profiled surface, and also serves to provide overall structural rigidity and impose overall structural constraints in the deformation simulation. Because the shell unit is built on the finite element model of the finished piece, the rigidity of the shell unit is higher, the rigidity and the shape of the molding surface of the mold can be simulated, and the thermal expansion coefficient of the material adopted by the shell unit can be adjusted to simulate the interaction of the mold and the finished piece in different degrees, the complete finite element model of the mold does not need to be built like a shear layer method. The shear modulus of the shear layer material of the shear layer method is inversely deduced according to the interaction degree, the thermal expansion coefficient of the die material is not the thermal expansion coefficient of the actual die material, and the material parameters adopted by the invention also reflect the interaction degree.
(2) The parameters of the die material are determined by the deformation result of the flat plate verification piece which is symmetrically layered, the shape of the verification piece is simple, the verification piece is in a single-curved-surface cylindrical shape after being deformed, the thickness is small, enough deformation is easy to generate, and the deformation amount is easy to measure; in addition, because the factors causing the deformation of the symmetrical laying composite material flat plate only relate to the interaction between the workpiece and the mould, the anisotropic thermal expansion characteristic and the chemical shrinkage characteristic of the material do not need to be considered, and the required input material parameters are simple.
(3) The finite element model does not relate to the problem of interface contact, so that the problem of nonlinearity is avoided, the calculated amount is small, and the convergence is good.
Drawings
FIG. 1 is a schematic view of a finite element model of a part of a composite fan blade in an embodiment
FIG. 2 is a schematic view of a finite element model of a verification member of the composite material flat verification member in the embodiment
FIG. 3 is a schematic diagram showing the deformation and the deformation amount of the composite material flat plate verification member in the embodiment after curing and demolding
FIG. 4 shows the simulation result of curing deformation of the composite material flat panel inspection piece in the example
FIG. 5 shows the simulation results of the curing deformation of the composite fan blade in the examples
The technical scheme of the invention is further detailed in the following by combining the drawings and the embodiment:
in this embodiment, taking a composite fan blade as an example, the method of the present invention is used to perform simulation prediction on the curing deformation of a composite material caused by the interaction between a workpiece and a mold, and the steps are as follows:
step S1: and constructing a finite element model of the part of the composite material part.
When the composite material fan blade is modeled, the geometric structure of the composite material fan blade is reasonably simplified, and then a product entity unit 1 is built, wherein the characteristic dimension of a film surface unit is 5mm, and the film surface unit is formed by a pentahedron and a hexahedron grid. The grids are divided in a sweeping mode from the middle surface to the outer surface so as to ensure the consistency of the unit directions, the Z direction of the solid unit 1 of the workpiece changes along with the change of the curvature of the blade, and the Z direction of each unit is consistent with the normal direction of the middle surface at the corresponding position. The composite material blade is molded by prepreg through a double-sided die, and after the composite material blade is subjected to solid unit meshing, the film sticking surfaces on the two sides of the suction surface and the pressure surface of the composite material blade are subjected to shell unit meshing; the node of the shell unit 2 of the workpiece mould and the solid unit of the blade share a node, and the thickness is set to be 1mm. The finite element model of the composite material fan blade is shown in FIG. 1, and the actual thickness of a solid unit 1 and a die shell unit 2 of a workpiece in the thickness direction is also shown in an enlarged mode in FIG. 1; the composite material blade is made of T800 carbon fiber reinforced 5228 epoxy resin prepreg, and the material parameters adopt the material parameters of the resin after gelation and before glass transition; the material of the shell unit 2 of the product mold adopts an isotropic material, and the modulus of the isotropic material is set to be 1 multiplied by 10 8 The MPa is much larger than the modulus of the composite material in the fiber direction, so that the rigidity of the part die shell unit 2 is ensured to be large enough, and only isotropic thermal expansion occurs without deformation caused by the influence of the composite material.
Step S2: constructing a finite element model of a verification piece of the composite material flat plate verification piece;
the length of the flat plate certificate checking piece is designed to be 450mm, and the width is designed to be 220mm; the layering angle of the composite material blade close to the film surface is [0/45/0/-45], so that the flat plate inspection certificate adopts [0/45/0/-45] s and has the thickness of 1.47mm; a verification piece entity unit 3 of the composite material flat verification piece is established by a hexahedron unit, and the characteristic size of a film pasting surface unit is 5mm, as shown in figure 2; the lower surface film pasting surface of the flat plate is subjected to grid division by adopting a shell unit, a node of a verification piece mold shell unit 4 and a verification piece entity unit 3 share a node, the thickness is set to be 1mm, and the actual thickness of the verification piece entity unit 3 and the verification piece mold shell unit 4 in the thickness direction is shown in an enlarged mode in figure 2; the verification piece solid unit 3 adopts the same composite material parameters as the composite material fan blade product solid unit 1, and the verification piece mold shell unit 4 adopts the same material modulus as the composite material fan blade product mold shell unit 2.
And step S3: preparing composite material flat plate verification sheet, measuring deformation value after forming and demoulding
45# steel is adopted for a forming die of the composite material blade, and the material is also adopted for a die of the flat plate verification piece; the size of the die of the flat plate certificate checking piece is 500mm multiplied by 300mm, and the thickness is 18mm; forming a composite material flat plate with the size of 450mm multiplied by 220mm and the thickness of 1.47mm by adopting T800 carbon fiber reinforced 5228 epoxy resin prepreg according to the sequence of [0/45/0/-45] s, wherein the curing temperature is 180 ℃, and the curing time is 2h; after the curing and demolding, the flat plate was deformed into an approximately cylindrical shape, the cylindrical shape was placed on a horizontal plane in the manner of fig. 3 and the maximum height h of the cylindrical arch was measured, which was 5.81mm.
And step S4: simulating the deformation of the composite material flat plate verification piece to obtain the thermal expansion coefficient of the mold;
adopting the finite element model of the verification piece established in the step S2 to calculate the deformation of the composite material flat plate verification piece, setting different thermal expansion coefficients of materials of the verification piece mold shell unit 4 for calculation, symmetrically constraining the middle surfaces of the flat plate and the mold in the length and width directions, fixing the central point of the lower surface of the constrained flat plate, applying a temperature load of 50-180 ℃, submitting the calculation and deriving stress from the calculation result; the finite element model of the verification piece is stored into a new model, the verification piece mold shell unit 4 is deleted, only the verification piece entity unit 3 is left, and the derived stress is applied to the verification piece entity unit 3, so that the serial numbers and positions of the units and nodes in the new model can be ensured to be consistent with the model when the stress is calculated, and the introduced stress can correctly correspond to each unit; deleting the temperature load and the constraint condition, and reapplying a new constraint condition constraint on the verification piece entity unit 3Rigid body displacement, modifying the performance parameters of the composite material into the performance parameters after glass transition, and submitting to calculation; when the thermal expansion coefficient of the material of the verifying piece mold shell unit 4 is 7.2 multiplied by 10 -7 K -1 Meanwhile, the calculated solidification deformation simulation result is shown in fig. 4; the maximum deformation of the workpiece in the Z direction (thickness direction) was 5.93mm, and the deformation mode of the simulation result was the same as that of the actual test piece, and the error from the measurement value was about 2.1%.
Step S5: simulating the deformation of the composite material part caused by the interaction of the part and the die, and setting the thermal expansion coefficient of the material of the part die shell unit 2 corresponding to the male die of the blade pressure surface to be 7.2 multiplied by 10 in the finite element model of the part established in the step S1 -7- K 1 (ii) a The thermal expansion coefficient of the material of the workpiece mould shell unit 2 corresponding to the female mould of the suction surface of the blade is 4.0 multiplied by 10 -7- K 1 (ii) a After the thermal expansion coefficient of the material of the shell unit 2 of the workpiece mould is set, the deformation of the fan blades of the composite material is calculated, and the specific process is as follows: fixing and restraining the root of the blade, applying a temperature load with a gel point of 50-180 ℃ to simulate a heating process, submitting calculation and deriving stress from a calculation result; additionally storing the finite element model of the workpiece into a new model, deleting the die shell unit 2 of the workpiece in the new model, only leaving the solid unit 1 of the workpiece, and applying the derived stress to the solid unit 1 of the workpiece, so that the serial numbers and positions of the unit and the node in the new model can be ensured to be consistent with the model when the stress is calculated, and the introduced stress can correctly correspond to each unit; deleting the temperature load and the constraint condition, applying a new constraint condition to the manufactured solid body unit 1 again to constrain the rigid body displacement, modifying the performance parameters of the composite material into the performance after glass transition, submitting to calculation, and finally obtaining the simulation result of deformation of the composite material blade caused by interaction of the manufactured part and the mold, as shown in fig. 5.
Claims (10)
1. A method of simulating composite material deformation caused by part-mold interaction, comprising: the method comprises the following steps:
step one, constructing a part finite element model of a composite material part, wherein in the part finite element model, a shell unit is adopted to perform grid division on a film pasting surface of a part entity unit (1), a part mould shell unit (2) is established for simulating the effect of a mould on the composite material part, the part mould shell unit (2) is matched with the part entity unit (1), the material parameters of the composite material part adopt the material parameters of resin before the glass transition after the resin is in gel, the material of the part mould shell unit (2) adopts an isotropic material, and the modulus of the isotropic material is far greater than that of the composite material in the fiber direction so as to ensure that the part mould shell unit (2) has enough rigidity;
step two, constructing a verification piece finite element model of the composite material flat plate verification piece, wherein in the verification piece finite element model, a shell unit is adopted to carry out grid division on a film pasting surface of a verification piece entity unit (3), a verification piece mold shell unit (4) is established to be used for simulating the effect of a mold on the composite material flat plate verification piece, the verification piece mold shell unit (4) is matched with the verification piece entity unit (3), the material parameters of the composite material flat plate verification piece adopt the material parameters before the vitrification transformation of resin after the gelation, the material of the verification piece mold shell unit (4) adopts an isotropic material, and the modulus of the material is far larger than that of the composite material fiber direction so as to ensure that the verification piece mold shell unit (4) has enough rigidity;
step three, preparing the composite material flat plate verification piece by adopting the same forming mode as the composite material part, wherein the die adopts a single-sided die, the composite material and the die material which are the same as the composite material part are adopted, and the thickness of the die can ensure that the die does not deform in the forming process; curing the flat plate verification piece by adopting the same technological parameters as those of the composite material product, and measuring a specific deformation value after demolding after curing;
step four, calculating the deformation of the composite material flat verification piece by using the verification piece finite element model established in the step two, comparing the deformation calculation result and the measurement result of the composite material flat verification piece, if the results are inconsistent, adjusting the thermal expansion coefficient of the material of the verification piece mold shell unit (4) for recalculation until the error of the calculation result compared with the measurement result is less than 5%, wherein the calculation process comprises the following steps:
applying constraint conditions to constrain rigid body displacement on a finite element model of a verification piece;
applying a temperature load from the gel point temperature to the curing temperature on the finite element model of the verification piece to simulate a heating process, submitting calculation and deriving stress from a calculation result;
storing the finite element model of the verification piece into a new model, and deleting the die shell unit (4) of the verification piece in the new model to only leave the entity unit (3) of the verification piece;
applying the derived stress to a verification piece entity unit (3) of the new model, deleting the temperature load and the constraint condition, applying a new constraint condition to the verification piece entity unit (3) again to constrain rigid body displacement, modifying the performance parameters of the composite material into the performance parameters after glass-transition, and submitting to calculation;
and step five, multiplying the thermal expansion coefficient of the material of the verification piece mold shell unit (4) determined in the step four by a coefficient of 0.1-3 to serve as the material parameter of the part finite element model part mold shell unit (2) constructed in the step one, then repeating the calculation process of the step four, replacing the verification piece finite element model with a part finite element model, and finally obtaining a simulation result of the curing deformation of the composite material part caused by the interaction of the part and the mold.
2. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the solid unit (1) of the part in the step one is established by adopting a pentahedron or hexahedron unit based on a geometric model of the composite material part.
3. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the matching of the product mold shell unit (2) and the product solid unit (1) in the step one means that the product mold shell unit (2) and the product solid unit (1) share a node.
4. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the matching of the workpiece mold shell unit (2) and the workpiece solid unit (1) in the first step means that the ratio of the unit characteristic size of the film sticking surface of the workpiece solid unit (1) to the thickness of the workpiece mold shell unit (2) is more than 2.
5. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the verification piece entity unit (3) in the step two is established by adopting a pentahedron or hexahedron unit based on a geometric model of the composite material flat verification piece.
6. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the verification piece mold shell unit (4) is matched with the verification piece entity unit (3) in the step two, namely the verification piece mold shell unit (4) and the verification piece entity unit (3) share a node.
7. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the verification piece mold shell unit (4) is matched with the verification piece entity unit (3) in the second step, namely the ratio of the unit characteristic size of the film sticking surface of the verification piece entity unit (3) to the thickness of the verification piece mold shell unit (4) is larger than 2.
8. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: in the second step, the verifying piece mold shell unit (4) adopts the same material modulus and thickness as the workpiece mold shell unit (2), and the verifying piece entity unit (3) adopts the same material parameters as the workpiece entity unit (1).
9. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: and in the second step, the entity unit (3) of the certificate inspection card adopts symmetrical layering, the thickness is 1-2 mm, and the layering angle is determined based on 1-8 layering angles of the film surface of the entity unit (1) of the workpiece.
10. The method of simulating composite material deformation caused by article-mold interaction of claim 1, wherein: the composite material is a fiber reinforced thermosetting resin-based composite material; the molding process is that the prepreg is heated and pressurized and cured by adopting a single-sided or double-sided mould, or the resin is injected into the fiber preform and then is vacuumized and heated and cured by adopting the single-sided mould, or the resin is injected into the fiber preform and then is heated and cured by adopting a double-sided closed mould.
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| CN106682284A (en) * | 2016-12-09 | 2017-05-17 | 中国商用飞机有限责任公司 | Analogue simulation method of composite material member hot-sizing process |
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