CN110884161A - 弯曲欧米伽桁条和z形复合材料桁条的制造方法以及具有曲率的复合材料加筋板的制造方法 - Google Patents

弯曲欧米伽桁条和z形复合材料桁条的制造方法以及具有曲率的复合材料加筋板的制造方法 Download PDF

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CN110884161A
CN110884161A CN201910858135.4A CN201910858135A CN110884161A CN 110884161 A CN110884161 A CN 110884161A CN 201910858135 A CN201910858135 A CN 201910858135A CN 110884161 A CN110884161 A CN 110884161A
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佩德罗·诺盖洛斯·维涅斯
玛丽亚·莫拉·门迪亚斯
弗朗西斯科·哈维尔·查莫罗·阿朗索
阿奎里诺·加西亚·加西亚
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Abstract

一种弯曲欧米伽复合材料桁条(1)的制造方法，包括以下步骤：在ATL机或AFP机或FLU机中进行自动铺带，并自动切割轮廓，然后实现带有增强件(7)的直的预成型件；平直成形，以在所述直的预成型件上得到欧米茄形状(3)，从而将所述直的预成型件转变成直的欧米茄形预成型件(2)；和弯曲成形步骤，其中，所述直的欧米茄形预成型件(2)放置在柔性工具(4)中，所述柔性工具(4)包括纵向嵌入的刚性带(9)和一些层压夹持装置(8)，所述层压夹持装置(8)位于所述柔性工具(4)的末端，所述柔性工具(4)由机械闭合装置覆盖，使得直的欧米茄形预成型件(2)头部的两个末端上具有增强件(7)，所述增强件(7)在成形工艺中由所述层压夹持装置(8)保持，然后将所述直的欧米茄形预成型件(2)加热并转变成弯曲欧米茄桁条(1)。

Description

弯曲欧米伽桁条和Z形复合材料桁条的制造方法以及具有曲 率的复合材料加筋板的制造方法
技术领域
本发明涉及一种弯曲欧米茄桁条和Z形复合材料桁条的制造方法，所述桁条和方法可用于飞机中的具有曲率的复合材料加筋板(例如，机身壁板、风扇罩等)。
本发明还涉及具有曲率的复合材料加筋板的制造方法。
背景技术
目前，高曲率桁条由于其高曲率而手动制成。在一些制造方法中，存在自动切割织物图案，然后在凸模工具(male tool)上手工铺设织物图案的阶段。
US2013/0340928A1描述了一种用于将复合装料形成为成形的(contoured)复合叶片桁条的方法和加工装置，所述成形的复合叶片桁条包括细长冲头和沿其长度为柔性的细长模具。通过使用冲头将装料驱动到模具中来压制装料。冲头和模具安装在一对柔性板之间。与所述柔性板连接的压力机通过将柔性板弯曲成所需的轮廓来使装料成形。为了减少起皱，在将桁条从加工装置中取出之前，允许桁条在受约束的同时冷却至室温。
US2013/0036922A1涉及用于运输、放置和压实复合加强件的方法和装置。其公开了一种用于压实成形的细长复合铺设层(layup)的装置，所述成形的细长复合铺设层包括沿其长度为柔性的柔性第一和第二纤维增强树脂柔性部分。第一部分在第一平面内是柔性的，第二部分在第一平面内以及在第二平面内是柔性的。
US7708546B2涉及一种用于形成结构构件的装置，并提供一种用于由装料形成复合结构构件的方法和相关装置。装料可以设置在所述装置的第一模具上，并通过将第二模具或工具插入模具凹槽中而形成为由所述凹槽限定的所需构造。在一些情况下，第一模具可包括两个部分，这两个部分在横向方向上是可调节的，使得凹槽可通过第二模具或工具的插入而打开。第二模具或工具可以是基本上刚性的构件或可膨胀的囊状物。在任一种情况下，装料可以设置在第一模具上，成形，然后在第一模具上进一步处理，从而便于使装料与每个操作挂钩。
WO2010047980A1涉及一种用于形成高度成形的复合部件的方法和装置，公开了一种将扁平复合装料形成为成形的复合部件的方法，所述方法在形成装料时减少部件中的皱折。模具用于将一部分装料形成部件的最陡轮廓，同时在剩余部分的装料形成时在装料上保持张力。
尽管这些方法允许制造具有高曲率的桁条，但是希望获得具有高自动化水平的制造工艺，其避免桁条头部上的任何变形、波浪或皱折。
发明内容
因此，本发明的目的是提供一种用于制造具有高曲率的大而复杂的欧米茄桁条的自动方法，其避免了上述缺点。
本发明提供一种复合材料的弯曲欧米茄桁条的制造方法，包括以下步骤：
-在ATL机(“自动铺带”机)或AFP机(“自动纤维放置”机)或FLU机(“纤维铺设”机)中进行自动铺带，并自动切割轮廓，然后实现带有增强件的直的预成型件；
-平直成形，以在所述直的预成型件上得到欧米茄形状，从而将所述直的预成型件转变成直的欧米茄形预成型件；和
-弯曲成形步骤，其中，所述直的欧米茄形预成型件放置在柔性工具中，所述柔性工具包括纵向嵌入的刚性带(stiff band)和一些层压夹持装置，所述层压夹持装置位于所述柔性工具的末端，所述柔性工具由机械闭合装置覆盖，使得直的欧米茄形预成型件的头部的两个末端上具有增强件，所述增强件在成形工艺中由所述层压夹持装置保持，然后将所述直的欧米茄形预成型件加热并转变成弯曲的欧米茄桁条。
纵向嵌入的刚性带避免了在桁条头部长度上的任何变形，并且层压夹持装置允许清除可能出现在桁条头部的末端增强件中的波浪或皱折。
本发明还提供一种弯曲Z形复合材料桁条的制造方法，包括所述弯曲欧米茄复合材料桁条的制造方法的步骤以及将弯曲欧米茄桁条切割成两部分以获得两个弯曲Z形桁条的附加步骤。
本发明还提供一种具有曲率的复合材料加筋板的制造方法，所述板包括表皮，所述方法包括以下步骤：
-根据本发明所述的弯曲欧米茄复合材料桁条的制造方法制造至少一个弯曲欧米茄桁条；
-固化所述至少一个弯曲欧米茄桁条；以及
-将固化的所述至少一个弯曲欧米茄桁条与所述表皮一体化，以获得共结合(cobonded)的具有曲率的复合材料加筋板。
本发明还提供一种具有曲率的复合材料加筋板的制造方法，所述板包括表皮，所述方法包括以下步骤：
-根据本发明所述的弯曲欧米茄复合材料桁条的制造方法制造至少一个弯曲欧米茄桁条；
-将固化的所述至少一个弯曲欧米茄桁条与所述表皮一体化；以及
-将固化的所述至少一个弯曲欧米伽桁条与所述表皮共同固化，以获得共同固化的具有曲率的复合材料加筋板。
本发明还提供了相对于现有技术工艺的若干优点：
-它允许高质量和重复工艺，以获得欧米茄桁条的形状。
-它允许高自动化水平的制造工艺。
-它减少了批量生产中的经常性成本(recurrent costs)和前置时间。
本发明的其它特征和优点将从以下对几个实施例的详细描述中变得清楚，这些实施例说明了与附图有关的目的。
附图说明
图1是本发明方法的示意图。
图2是在本发明的中间步骤中获得的直的预成型件的透视图。
图3和图4示出了在本发明方法中使用的柔性工具。
图5示出了预成型件、柔性工具和真空袋的组装。
图6示出了用于弯曲成形的凸模工具以及具有预成型件的柔性工具。
图7示出了根据本发明方法制造的弯曲欧米伽桁条。
图8示出了具有层压夹持装置的柔性工具。
图9示出了根据本发明制造的Z形桁条。
具体实施方式
在图1中，概述了本发明所述的弯曲欧米茄复合材料桁条1的制造方法。
该方法的主要步骤是：
-在ATL机或AFP机或FLU机中进行自动铺带，并自动切割轮廓，然后实现带有增强件7的直的预成型件；
-平直成形，以在所述直的预成型件上得到欧米茄形状，从而将所述直的预成型件转变成直的欧米茄形预成型件2；和
-弯曲成形步骤，以获得弯曲欧米茄桁条1。
具有高曲率的欧米茄桁条1可以固化，然后与具有曲率的加筋板的表皮或飞机机身一体化，以获得共结合部分(如当前现有技术工艺中)，或者它可以直接与表皮一体化以获得共固化部分。
第一步包括自动铺带和自动切割。欧米茄桁条的预成型件由ATL机或AFP机或FLU机自动铺设，并且切割出轮廓。可以同时铺设多个预成型件，并且预成型件将在切割步骤之后实现。这节省了经常性成本和前置时间。
0°方向的板层只能位于桁条的头部，以便能够进行热成型工艺而不会产生皱折。
第二步包括平直成型以在直的预成型件上获得欧米茄形状3(参见图2)，将直的预成型件转变成直的欧米茄形预成型件2。可以使用热成型系统或压力机。
曲线形成步骤允许在桁条中获得高曲率。在该步骤中，直的欧米茄形预成型件2位于柔性工具4(图3和图4)中，以便能够形成没有皱折或波浪的桁条。
柔性工具4包含纵向嵌入的刚性带9，以避免桁条头部长度上的任何变形，并确保在成形工艺之后的正确几何形状。
柔性工具4可包括两个部分，如图3和图4所示。
纵向嵌入的刚性带9可以是金属带。
桁条(在此阶段为直的欧米茄形预成型件2)放置在柔性工具4中并由机械闭合装置，优选真空袋5覆盖，以产生具有真空的刚性固体并避免皱折(见图5)。
另外，一些层压夹持装置8位于柔性工具4的末端(参见图8)，以清除出现在桁条头部的末端加强件7中的波浪或皱折。在成形工艺中，增强件7可以交错制成并且比层压夹持装置8保持的层压板长。
优选地，层压夹持装置8可以是研磨装置；例如，它们可以由砂纸制成。
然后，将其加热并在所述工具上转变成弯曲欧米茄桁条1。在成形过程中需要有足够的真空以避免皱折。
研磨装置可以是研磨膜，柔性工具4可以由橡胶制成。
优选地，使用凸模工具6将直的欧米伽形预成型件2转变为弯曲欧米茄桁条1(参见图6和图7)。
根据上述方法制造的弯曲欧米茄桁条1可以被切割成两部分以获得两个弯曲Z形桁条10。
一种具有曲率的复合材料加筋板的制造方法，所述板包括表皮，所述方法包括以下步骤：
-根据上述方法制造至少一个弯曲欧米茄桁条1；
-固化所述至少一个弯曲欧米茄桁条1；以及
-将固化的所述至少一个弯曲欧米茄桁条1与所述表皮一体化，以获得共结合的具有曲率的复合材料加筋板。
具有曲率的复合材料加筋板的另一种制造方法，所述板包括表皮，所述方法包括以下步骤：
-根据上述方法制造至少一个弯曲欧米茄桁条1；
-将固化的所述至少一个弯曲欧米茄桁条1与所述表皮一体化；以及
-将固化的所述至少一个弯曲欧米茄桁条1与所述表皮共同固化，以获得共同固化的具有曲率的复合材料加筋板。
尽管已经结合优选实施例充分描述了本发明，但显然可以在本发明范围内引入修改，不应将本发明视为受这些实施例的限制，而是受所附权利要求的内容的限制。

Claims (12)

1.一种弯曲欧米伽复合材料桁条(1)的制造方法，包括以下步骤：
-在ATL机或AFP机或FLU机中进行自动铺带，并自动切割轮廓，然后实现带有增强件(7)的直的预成型件；
-平直成形，以在所述直的预成型件上得到欧米茄形状(3)，从而将所述直的预成型件转变成直的欧米茄形预成型件(2)；
其特征在于，所述方法还包括：
-弯曲成形步骤，其中，所述直的欧米茄形预成型件(2)放置在柔性工具(4)中，所述柔性工具(4)包括纵向嵌入的刚性带(9)和一些层压夹持装置(8)，所述层压夹持装置(8)位于所述柔性工具(4)的末端，所述柔性工具(4)由机械闭合装置覆盖，使得所述直的欧米茄形预成型件(2)的头部的两个末端上具有增强件(7)，所述增强件(7)在成形工艺中由所述层压夹持装置(8)保持，然后将所述直的欧米茄形预成型件(2)加热并转变成弯曲欧米茄桁条(1)。
2.根据权利要求1所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述平直成形步骤在压力机中进行。
3.根据权利要求1所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述平直成形步骤在热成形系统中进行。
4.根据前述权利要求中任一项所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述层压夹持装置(8)是研磨装置。
5.根据权利要求4所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述研磨装置由砂纸制成。
6.根据前述权利要求中任一项所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述柔性工具(4)由橡胶制成。
7.根据前述权利要求中任一项所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述机械闭合装置是真空袋(5)。
8.根据前述权利要求中任一项所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，所述纵向嵌入的刚性带(9)是金属带。
9.根据前述权利要求中任一项所述的弯曲欧米伽复合材料桁条(1)的制造方法，其中，使用凸模工具(6)将所述直的欧米茄形预成型件(2)转变成弯曲欧米茄桁条(1)。
10.一种弯曲Z形复合材料桁条(10)的制造方法，包括权利要求1至9中任一项所述的方法的步骤以及将所述弯曲欧米茄桁条(1)切割成两部分以获得两个弯曲Z形桁条(10)的附加步骤。
11.一种具有曲率的复合材料加筋板的制造方法，所述板包括表皮，其特征在于，所述方法包括以下步骤：
-根据权利要求1至9中任一项制造至少一个弯曲欧米茄桁条(1)；
-固化所述至少一个弯曲欧米茄桁条(1)；以及
-将固化的所述至少一个弯曲欧米茄桁条(1)与所述表皮一体化，以获得共结合的具有曲率的复合材料加筋板。
12.一种具有曲率的复合材料加筋板的制造方法，所述板包括表皮，其特征在于，所述方法包括以下步骤：
-根据权利要求1至9中任一项制造至少一个弯曲欧米茄桁条(1)；
-将固化的所述至少一个弯曲欧米茄桁条(1)与所述表皮一体化；以及
-将固化的所述至少一个弯曲欧米茄桁条(1)与所述表皮共同固化，以获得共同固化的具有曲率的复合材料加筋板。
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