CN110815856A - Soft die manufacturing method for forming I-beam composite material part and application thereof - Google Patents
Soft die manufacturing method for forming I-beam composite material part and application thereof Download PDFInfo
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- CN110815856A CN110815856A CN201911176671.2A CN201911176671A CN110815856A CN 110815856 A CN110815856 A CN 110815856A CN 201911176671 A CN201911176671 A CN 201911176671A CN 110815856 A CN110815856 A CN 110815856A
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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
- B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
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Abstract
The invention discloses a method for manufacturing a soft die for forming an I-beam composite material part and application thereof. The soft mold has simple manufacturing process, short period and low cost of raw materials. The I-beam composite material part formed by the flexible membrane can uniformly and accurately transfer the pressure applied by the autoclave, avoid the phenomenon of the composite material part with over-thickness difference, ensure the forming quality of the part, and improve the qualification rate and efficiency of production and the molded surface and size precision of the part after forming. In addition, compared with the traditional air nozzle structure, the air nozzle structure has the advantages of reduced air tightness requirement, longer service life, higher reliability, simpler and more convenient field use, later maintenance and the like, and good use value.
Description
Technical Field
The invention relates to a method for manufacturing a soft die for forming an I-beam composite material part and application thereof.
Background
The resin-based carbon fiber composite material has superior performances of high specific strength and specific stiffness, strong designability, good fatigue fracture resistance, corrosion resistance, good dimensional stability and the like, and is a high-performance structural material which is widely applied in the fields of aviation, aerospace, traffic and the like at present. In the molding process of various carbon fiber composite materials, the autoclave process has uniform molding temperature and pressure and good adaptability to parts of different materials, shapes, sizes and structures, thereby becoming one of the main process methods for researching and manufacturing aerospace high-quality composite material components.
The i-beam structure is a common reinforcing structural member in a composite material part, and is generally divided into structural forms such as an i-beam with a uniform cross section and an i-beam with a variable cross section, and is generally characterized by a large size and a thin wall thickness, and a part of the i-beam part is provided with a hyperboloid structure, as shown in fig. 1 and 2. Composite material parts manufactured by the existing process method are deformed to a certain degree after being molded, and parts with thin wall thickness are particularly obvious. Therefore, the technical difficulty of the thin-wall I-beam forming lies in how to control the profile degree, thickness and deformation of a part, and simultaneously, the manufacturing period and cost are reduced as much as possible, and the manufacturing power is improved.
At present, the forming process of the variable cross-section thin-wall I-beam composite material structural member in the industry is mainly a forming method based on an autoclave process. The co-curing is used as the most hot manufacturing mode and means in the current autoclave process and has the characteristics of high structural strength, small specific gravity, low cost and the like; meanwhile, the co-curing process requires that the pressure of the part is always balanced in the forming process, and the integral deformation of the part is small, so that a very strict process requirement is provided for co-curing of the part with the large size and the variable cross section.
However, the forming process of the present variable cross-section thin-wall i-beam composite structural member is basically core mold forming or air bag forming. In the core mold forming process, the core mold is generally made of mold steel or aluminum alloy. Taking a simple i-beam structural member as an example, the forming method is shown in fig. 3; the rubber air bag is communicated with the outside through the air tap, the pressure is uniformly transmitted to the composite material part, the pressure of the left air bag and the pressure of the right air bag are balanced, the thickness and the overall dimension of the I-beam can be ensured to meet the design requirements, and the forming method is shown in figure 4. The disadvantages of forming i-beams using these two processes are mainly several: 1) because the core mould has certain rigidity, the external pressure is difficult to be uniformly and accurately transmitted through the core mould, the thickness of a variable cross-section thin-wall composite material part is easy to be out of tolerance, and the requirement of thickness tolerance is difficult to be met. 2) Because the core mold has a certain thickness and is not uniform in thickness, the heating rates of different areas of the product are different according to the heat transfer effect, so that the internal forming quality of the product is influenced, and the product is cooled and demoulded to generate a large deformation amount; meanwhile, the large parts with violent thickness change and more lost layer areas have higher requirements on the combination of metal molds, and the common mold forming mode cannot meet the civil aircraft nondestructive requirements. 3) Because the core mould is made of metal, the dead weight is large, and the operation is very inconvenient. Meanwhile, the manufacturing and maintenance cost of the metal core mold is high, and the manufacturing period of repair or rework is long. 4) According to the traditional process, the requirements on the manufacturing and matching precision of the mold cores on the two sides of the web plate of the I-beam are high, the I-beam is generally made of invar steel, the cost is extremely high, and after the mold deforms in the using process, the product is free of damage and the thickness cannot be guaranteed. 5) The I-beam is formed by using the air bag method, although the uniform transmission of external pressure and heat can be ensured, the manufacturing process of the air bag is complex, the air bag is easy to crack or damage near the air nozzle, and the manufacturing power is low; meanwhile, the process method has a strict air tightness requirement on the air bag, once air leakage occurs, repair cannot be usually carried out, so that the service life and the reliability of the air bag are reduced, and the process is particularly obvious in the forming process of large-size composite material parts.
Disclosure of Invention
Aiming at the existing problems, the invention provides a method for manufacturing a soft die for forming an I-beam composite material part and application thereof. The specific technical scheme is as follows:
the invention provides a method for manufacturing a soft die for forming an I-beam composite material part, which comprises the following steps:
1) manufacturing a fake part and a mould: through a mechanical manufacturing method, a set of I-beam metal dummy pieces which are completely consistent with the shape and size of an I-beam composite material part are processed, and a set of soft die forming die for manufacturing a soft die is manufactured at the same time, wherein the soft die forming die and the I-beam metal dummy pieces are in a matching relation and play a limiting role at the same time;
2) assembling and paving materials: assembling the I-beam metal dummy piece manufactured in the step 1) and a soft die forming die together according to a matching relationship, wherein two sides of the I-beam metal dummy piece and the soft die forming die form an open cavity with a U-shaped section; paving and sticking the rubber material for manufacturing the soft mold in the open cavity according to requirements, and packaging the rubber material on the I-beam metal dummy piece and the soft mold forming mold;
3) curing and forming: and (3) conveying the whole tool paved with the rubber material in the step 2) into an autoclave, curing and forming the rubber material under the conditions of high temperature and high pressure according to the curing process of the rubber, taking the rubber material out of the autoclave, cooling and demoulding to obtain the soft mould for forming the I-beam composite material part.
As an optimal technical scheme, in the step 1), the soft mold forming mold comprises an upper mold plate and a lower mold plate, and the corresponding inner side surfaces of the upper mold plate and the lower mold plate are respectively provided with a clamping groove matched with the upper surface and the lower surface of the i-beam metal part, so that the matching and limiting effects are achieved during assembly.
As a preferable technical scheme, in the step 2), the rubber material for manufacturing the soft mold is silicon rubber, and a reinforcing layer formed by fiber prepreg is paved between the silicon rubber and the reinforcing layer, so that the overall rigidity of the soft rubber mold is improved.
Preferably, the paving sequence of the rubber material for manufacturing the soft mold and the reinforcing layer is as follows: rubber layer-fibrous prepreg layer-rubber layer.
Further preferably, the fiber prepreg is a carbon fiber prepreg or a glass fiber prepreg.
As a preferable technical scheme, the specific number of layers of the laid rubber and the fiber prepreg depends on the size and the structural complexity of an I-beam composite material part; wherein, the number of the rubber laying layers is generally 2-4, and the number of the fiber prepreg laying layers is generally 2-8.
The method for manufacturing the soft mold for molding the i-beam composite material part according to claim 1, wherein in the step 2), the packaging is performed by vacuum-pumping the i-beam metal dummy part and the soft mold molding mold by using a vacuum bag and a sealing rubber strip.
The invention also provides a use method of the soft mold for forming the I-beam composite material part, wherein the soft mold manufactured according to the method is used as a part of the forming mold of the I-beam composite material part and is matched with the manufactured soft mold forming mold to finish the manufacturing process of the I-beam composite material part.
The invention has the beneficial effects that:
compared with the prior art, the invention has the following advantages:
1. compared with the traditional core mold forming method, the soft mold can uniformly and accurately transfer the pressure applied by the autoclave, and avoids the phenomenon of over-thickness of a composite material part;
2. the soft mold is thin in wall thickness, so that the thermal hysteresis effect can be avoided, the molding quality of a workpiece can be effectively ensured, and the yield and the efficiency of production are improved;
3. the soft mold has certain rigidity and shaping capability due to the existence of the carbon fiber or glass fiber reinforced layer, so that the molded surface and the dimensional accuracy of a molded part are ensured;
4. the open type rubber soft mold abandons the traditional air nozzle structure, the air tightness requirement is reduced, so the open type rubber soft mold has longer service life and higher reliability, the soft mold manufacturing process is simplified, and the manufacturing period and the raw material cost are reduced;
5. the soft mold can not influence the product molding quality due to self deformation, and is simple and convenient in field use and later maintenance.
Drawings
FIGS. 1 and 2 are schematic structural views of an I-beam composite article of the present invention;
FIG. 3 is a schematic view of a prior art I-beam composite part formed using a core mold;
FIG. 4 is a schematic view of a prior art method of forming an I-beam composite part using an air bag mold;
FIG. 5 is an assembly view of the I-beam metal dummy and the soft mold forming mold according to the present invention;
FIG. 6 is a schematic view of the soft mold lay-up of the present invention;
FIG. 7 is a schematic diagram of a soft mold package structure according to the present invention;
FIG. 8 is a schematic view of the soft mold for forming an I-beam composite material part.
In the figure: 1. an I-beam composite part; 2. i-beam metal dummy; 3. a soft mold forming mold; 31. mounting a template; 32. a lower template; 4. a card slot; 5. soft molding; 51. a rubber layer; 52. a fibrous prepreg layer; 6. vacuum bag; 7. sealing rubber strips; 8. a core mold; 9. an air bag; 10. an air tap.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the present embodiment, belong to the protection scope of the present invention.
Example 1
The embodiment provides a method for manufacturing a soft mold for forming an I-beam composite material part, which comprises the following steps:
1) manufacturing a fake part and a mould: through a mechanical manufacturing method, a set of I-beam metal dummy pieces 2 which are completely consistent with the shape and size of an I-beam composite material piece 1 are processed, a set of soft mold forming mold 3 for manufacturing a soft mold is manufactured at the same time, the soft mold forming mold 3 comprises an upper mold plate 31 and a lower mold plate 32, and clamping grooves 4 which are matched with the upper surface and the lower surface of the I-beam metal dummy pieces 2 are formed in the corresponding inner side surfaces of the upper mold plate 31 and the lower mold plate 32, so that the matching and limiting effects are achieved during assembly, and as shown in fig. 5.
2) Assembling and paving materials: assembling the metal dummy piece manufactured in the step 1) and the soft mold forming mold together according to a matching relationship, wherein two sides of the I-beam metal dummy piece 2 and two sides of the soft mold forming mold 3 form an open cavity with a U-shaped section; and paving the material for manufacturing the soft mold 5 in the open cavity according to requirements. The soft mold 5 is made of rubber, and a reinforcing layer formed by fiber prepreg is paved in the middle of the soft mold to improve the overall rigidity of the soft mold; the paving sequence is as follows: rubber layer 51-fibrous prepreg layer 52-rubber layer 51. The rubber layer 51 is made of silicone rubber, and the fiber prepreg layer 52 is made of carbon fiber prepreg or glass fiber prepreg, as shown in fig. 6. The specific number of the paving rubber layer 51 and the fiber prepreg layer 52 depends on the size and the structural complexity of the I-beam composite material part 1; wherein, the number of the rubber laying layers is generally 2-4, and the number of the fiber prepreg laying layers is generally 2-8.
After the laying, the I-beam metal dummy part 2 and the soft mold forming mold 3 are packaged by using a vacuum bag 6 and a sealing rubber strip 7 in a vacuumizing mode, as shown in fig. 7.
3) Curing and forming: sending the whole tool paved with the rubber material in the step 2) into an autoclave, and curing and molding the rubber material under the conditions of high temperature and high pressure according to the curing process of the rubber, wherein the curing process parameters are as follows: high temperature 150-200 deg.c and high pressure 0.3-0.7 MPa; and after the solidification is finished, taking out the tank, cooling and demolding to obtain the soft mold 5 for molding the I-beam composite material workpiece.
Example 2
In this embodiment, a soft mold 5 manufactured according to the method described in embodiment 1 is used as a part of a mold for forming an i-beam composite material part 1, and is matched with a manufactured soft mold forming mold 3 to complete a manufacturing process of manufacturing the i-beam composite material part 1, as shown in fig. 8. The specific process flow is as follows:
firstly, two sets of preforming tools are manufactured, U-shaped assemblies on two sides of an i-beam composite material part are paved on the manufactured preforming tools, and after paving is completed, the U-shaped assemblies are taken off from the preforming tools and paved on the soft die 5 for forming the i-beam composite material part manufactured in the embodiment 1. Paving and pasting a top plate of an I-beam composite material part in a clamping groove 4 of an upper template 31 of the soft mold forming mold 3 in embodiment 1 while paving and pasting the U-shaped component; and paving a bottom plate of the I-beam composite material part in the clamping groove 4 of the lower template 31. And then assembling the soft mold 5 with the U-shaped assembly and the forming mold 3 with the top plate and the bottom plate of the I-beam composite material part, carrying out vacuum packaging by using a vacuum bag and a sealing rubber strip, then sending into an autoclave for hot-pressing curing forming, taking out of the autoclave, cooling and demolding to obtain the I-beam composite material part 1.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. Furthermore, it should be understood that the above description is only one preferred embodiment of the present invention, and is not intended to limit the present invention in any way, as those skilled in the art may change or modify the equivalent embodiments using the technical disclosure described above. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention are within the protection scope of the technical solution of the present invention.
Claims (8)
1. A method for manufacturing a soft die for forming an I-beam composite material part is characterized by comprising the following steps of: the method comprises the following steps:
1) manufacturing a fake part and a mould: through a mechanical manufacturing method, a set of I-beam metal dummy pieces which are completely consistent with the shape and size of an I-beam composite material part are processed, and a set of soft die forming die for manufacturing a soft die is manufactured at the same time, wherein the soft die forming die and the I-beam metal dummy pieces are in a matching relation and play a limiting role at the same time;
2) assembling and paving materials: assembling the I-beam metal dummy piece manufactured in the step 1) and a soft die forming die together according to a matching relationship, wherein two sides of the I-beam metal dummy piece and the soft die forming die form an open cavity with a U-shaped section; paving and sticking the rubber material for manufacturing the soft mold in the open cavity according to requirements, and packaging the rubber material on the I-beam metal dummy piece and the soft mold forming mold;
3) curing and forming: and (3) conveying the whole tool paved with the rubber material in the step 2) into an autoclave, curing and forming the rubber material under the conditions of high temperature and high pressure according to the curing process of the rubber, taking the rubber material out of the autoclave, cooling and demoulding to obtain the soft mould for forming the I-beam composite material part.
2. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 1, wherein the method comprises the following steps: in the step 1), the soft mold forming mold comprises an upper template and a lower template, and the corresponding inner side surfaces of the upper template and the lower template are respectively provided with a clamping groove matched with the upper surface and the lower surface of the I-beam metal piece, so that the matching and limiting effects are achieved during assembly.
3. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 1, wherein the method comprises the following steps: in the step 2), the rubber material for manufacturing the soft mold is silicon rubber, and a reinforcing layer formed by fiber prepreg is paved in the middle of the silicon rubber so as to improve the overall rigidity of the soft rubber mold.
4. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 3, wherein the method comprises the following steps: the paving sequence of the rubber material for manufacturing the soft mold and the reinforcing layer is as follows: rubber layer-fibrous prepreg layer-rubber layer.
5. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 4, wherein the method comprises the following steps: the fiber prepreg is a carbon fiber prepreg or a glass fiber prepreg.
6. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 4, wherein the method comprises the following steps: the specific number of layers of the laid rubber and the fiber prepreg depends on the size and the structural complexity of the I-beam composite material part; wherein, the number of the rubber laying layers is generally 2-4, and the number of the fiber prepreg laying layers is generally 2-8.
7. The method for manufacturing the soft mold for molding the I-beam composite material part according to claim 1, wherein the method comprises the following steps: in the step 2), the packaging is carried out by using a vacuum bag and a sealing rubber strip to package on the I-beam metal dummy piece and the soft mold forming mold in a vacuumizing mode.
8. A soft die using method for forming an I-beam composite material part is characterized by comprising the following steps: the soft mold manufactured according to the method of claims 1 to 7 is used as a part of a forming mold of an i-beam composite material part, and is matched with the soft mold forming mold of claim 2 to complete the manufacturing process of the i-beam composite material part.
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| CN111923453A (en) * | 2020-06-22 | 2020-11-13 | 成都飞机工业（集团）有限责任公司 | Female die soft film forming tool for internal flatness of mouth-shaped part and control method |
| CN112123811A (en) * | 2020-07-24 | 2020-12-25 | 北京卫星制造厂有限公司 | Forming method of split tooling composite material bracket |
| CN112606434A (en) * | 2020-12-14 | 2021-04-06 | 陕西天翌天线股份有限公司 | Auxiliary forming method for thermal expansibility core die of H-shaped beam and H-shaped beam |
| CN113320117A (en) * | 2021-06-21 | 2021-08-31 | 刘烈新 | Continuous special-shaped component soft mold and manufacturing method thereof |
| CN114379113A (en) * | 2021-12-31 | 2022-04-22 | 天津爱思达航天科技有限公司 | I-beam forming die and forming process |
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| CN114379113A (en) * | 2021-12-31 | 2022-04-22 | 天津爱思达航天科技有限公司 | I-beam forming die and forming process |
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| CN115071022B (en) * | 2022-06-21 | 2023-08-22 | 中国人民解放军国防科技大学 | Hot-press forming device and method for T-shaped thermoplastic composite material workpiece |
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| CN115042453B (en) * | 2022-06-22 | 2024-03-08 | 沈阳飞机工业（集团）有限公司 | Thin-wall tool for manufacturing H-shaped variable-section honeycomb sandwich structure composite material part |
| CN117162539A (en) * | 2023-11-02 | 2023-12-05 | 成都泰格尔航天航空科技股份有限公司 | Compacting device and production process thereof |
| CN117162539B (en) * | 2023-11-02 | 2024-02-06 | 成都泰格尔航天航空科技股份有限公司 | Compacting device and production process thereof |
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