CN110948909A - Forming method of square equal-section large-size composite material box - Google Patents
Forming method of square equal-section large-size composite material box Download PDFInfo
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- CN110948909A CN110948909A CN201911264391.7A CN201911264391A CN110948909A CN 110948909 A CN110948909 A CN 110948909A CN 201911264391 A CN201911264391 A CN 201911264391A CN 110948909 A CN110948909 A CN 110948909A
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- box body
- prepreg
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- material box
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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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/007—Tempering units for temperature control of moulds or cores, e.g. comprising heat exchangers, controlled valves, temperature-controlled circuits for fluids
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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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
-
- 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
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Thermal Sciences (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention discloses a method for forming a square constant-section large-size composite material box body, which comprises the following steps of: 1) preparing a prepreg and an adhesive film; 2) preparing a metal mold; 3) cutting the prepreg; 4) according to the preset layering sequence; 5) placing an adhesive film; 6) pressing an R-angle die; 7) winding the demolding ring rib; 8) putting a vacuum bag into a tank for curing, arranging 2-3 vacuumizing positions on two sides of the mold respectively to ensure the vacuum state of the part, burying thermocouples in the inner cavity and the outer part of the mold, and monitoring the curing temperature of the box body; 9) external pressurization is carried out, the air tightness, the internal quality and the appearance quality of the box body are ensured simultaneously, external pressure is selected, and the temperature is determined by the selected prepreg resin system; 10) demolding the composite material box body; 11) after the composite material box body is subjected to a demolding procedure, the box body is molded after the surface is finished completely, and the problem of air tightness of the composite material box body is solved; improve the internal quality of the box body.
Description
Technical Field
The invention relates to a composite material box body, in particular to a composite material box body forming method.
Background
The traditional forming process of the square constant-section large-size composite material box body comprises a hand pasting process, a wet winding process and the like. The hand pasting process has low production efficiency, high labor intensity, poor labor sanitary conditions, difficult control of product quality, low performance stability and low mechanical properties of products. The wet winding process is to wind the twistless roving after soaking in resin glue solution onto the core mold, and the quality of the yarn sheet is not easy to control and test because the fiber yarn is wound immediately after soaking. Meanwhile, a large amount of solvent exists in the glue solution, bubbles are easily generated during curing, tension in the winding process is also not easy to control, and the situation that tension cannot be added to the side face of the composite material box body with the square section easily exists. Frequent maintenance and washing are needed for a dipping roll, a tension roll and the like, and the efficiency is low.
Disclosure of Invention
The invention aims to provide a method for forming a square constant-section large-size composite material box body, which solves the problem of air tightness of the composite material box body; the internal quality of the box body is improved, and the porosity is reduced; the mechanical property strength of the box body is improved; the problem of surface quality is solved, machining is not needed, and cost is reduced.
The purpose of the invention is realized as follows: a method for forming a square large-size composite material box with uniform cross section comprises the following steps:
step 1), preparing a prepreg and an adhesive film, taking out the unidirectional prepreg, the plain-weave prepreg and the adhesive film from a refrigeration house, and cooling at room temperature for later use;
step 2), preparing a metal mold, and cleaning the surface of the mold;
step 3) calculating the prepreg paving sequence meeting the use working condition of the box body by using Abaqus equal-strength calculation software according to the actual working condition of the box body, wherein the prepreg paving sequence is [45/-45/90/-45/0/45/90/45/0/90] s; cutting the prepreg according to the laying sequence, and cutting prepreg sheets at various angles required by laying by using an automatic cloth cutting machine for standby;
step 4) paving and pasting the prepreg on a mould according to a set paving sequence, wherein the prepreg is paved in an annular butt joint mode, and is paved in the same direction and at the same angle according to the principle of composite material pre-design;
step 5), placing adhesive films, namely placing the adhesive films after the 1 st layer and the 3 rd layer are paved, wherein the adhesive films are full-paved layers with 100 percent of area, the adhesive films are added at the positions close to the inner surface to ensure air tightness, and performing one-time vacuum pumping compaction process on each two layers of prepreg;
step 6), adding a thin-walled L-shaped glass fiber reinforced plastic pressing die to the R corner after all layers are laid;
step 7), winding the demolding ring ribs, and processing the ring ribs at two ends of the box body mold by using a winding process respectively;
step 8) putting a vacuum bag into the tank for curing, arranging 2-3 vacuumizing positions on two sides of the length direction of the mold respectively to ensure the vacuum state of the part, burying thermocouples in the inner cavity and the outer part of the mold, and monitoring the curing temperature of the box body;
step 9), externally pressurizing, simultaneously ensuring the airtightness, the internal quality and the appearance quality of the box body, and selecting external pressure and temperature determined by the selected prepreg resin system;
step 10), demolding the composite material box body;
and 11) performing a demolding procedure on the composite material box body, and finishing the forming of the box body after the surface is finished.
As a further limitation of the present invention, the cooling time in step 1) is 6 hours or more.
As a further limitation of the invention, step 2) designs the die to have a draft angle of 2 ° -3 °.
As a further limitation of the invention, when butt joint is needed in the layering process in the step 4), the distance between two splicing seams is not less than 25mm, and the splicing positions of each layer are staggered.
As a further limitation of the present invention, the external pressure in step 9) is 0.1-0.3 MPa.
Compared with the prior art, the invention has the beneficial effects that:
the traditional forming method adopted by the composite box body has the problems of low material utilization rate, serious environmental pollution and nonuniform quality; compared with the forming methods such as wet hand pasting and the like, the material utilization rate is high, and the forming site is clean; using autoclave process, inflating and pressurizing the autoclave by compressed air, wherein the pressures acting on the normal lines of all points on the surface of the vacuum bag are the same, so that the component is formed and cured under uniform pressure; the pressure and the temperature in the hot pressing tank are uniform, so that the stable quality of the formed box body can be ensured; the box body manufactured by the autoclave molding process has low porosity and uniform resin content, and has stable and reliable mechanical properties and good nondestructive condition compared with the autoclave manufacturing components manufactured by other molding processes.
When the composite box body formed by using the traditional hand pasting process and the like is subjected to an airtight test, the phenomenon of air leakage exists, secondary repair is needed, and the production efficiency is influenced; when the composite material box body formed by the autoclave process is subjected to an air tightness test, 100% of the composite material box body can pass through the autoclave process, and secondary repair is not needed.
The box body prepared by the prepreg paving and autoclave process forming method has good surface quality, does not need secondary machining, and reduces machining cost.
Drawings
FIG. 1 is a schematic view of a metal mold according to the present invention.
FIG. 2 is a schematic view of ply splicing according to the present invention.
FIG. 3 is a photograph showing the wrinkles in the R-angle region of the present invention.
FIG. 4 is a schematic diagram of the structure of the L-shaped glass fiber reinforced plastic press mold of the present invention.
Fig. 5 is a flow chart of the winding process of the present invention.
Fig. 6 is a schematic view of the demolding tool used in the present invention.
FIG. 7 is a photograph showing a composite material case manufactured in the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
A method for forming a square large-size composite material box with uniform cross section comprises the following steps:
step 1), taking out the unidirectional prepreg, the plain prepreg and the adhesive film from a refrigeration house, and cooling for more than 6 hours at room temperature for later use; the unidirectional prepreg has good mechanical strength but poor air tightness, so that plain prepreg and adhesive film are assisted, and the air tightness of the box body is ensured;
step 2) preparing a metal mold, cleaning the surface of the mold by using acetone, and treating the surface of the mold for more than 3 times by using a release agent. The composite material box body is large in size and long in length. If the cross-section is always consistent, demolding may be difficult. Therefore, the die is designed to have a die drawing angle of 2-3 degrees, so that the die is convenient to demould; the die design is shown in figure 1;
step 3) calculating the prepreg paving sequence meeting the use working condition of the box body by using Abaqus equal-strength calculation software according to the actual working condition of the box body, wherein the prepreg paving sequence is [45/-45/90/-45/0/45/90/45/0/90] s; cutting the prepreg according to the laying sequence, and cutting prepreg sheets at various angles required by laying by using an automatic cloth cutting machine for standby;
and 4) paving the prepreg on the mould according to the established paving sequence. The prepreg is laid in a circumferential butt joint mode, and according to the design principle of composite materials, when the layers laid in the same direction (angle) need to be in butt joint, the distance between two abutted seams is not less than 25 mm. Therefore, the splicing positions of each layer are staggered, and the distance is 25 mm. The specific splicing schematic diagram is shown in FIG. 2;
and 5) putting adhesive films after the 1 st layer and the 3 rd layer are laminated, wherein the adhesive films are 100% area full-laminated layers. The glue film is added at the position close to the inner surface to ensure air tightness. Because of large size, the procedure of vacuumizing and compacting once is required to be carried out when 2 layers of prepreg are paved;
step 6), because the composite material box body has a certain thickness, wrinkles can be formed in the R-angle area in the process of stacking accumulation, as shown in fig. 3. If vacuum curing is performed directly, wrinkles are inevitably formed at the corner R. In order to ensure the appearance quality, after all layers are laid, adding a thin-walled L-shaped glass fiber reinforced plastic pressing die at an R angle, as shown in figure 4;
and 7) winding the demolding ring ribs, wherein the ring ribs with the height of about 50mm are formed at two ends of the box body mold by winding processes for assisting demolding of the composite material box body. The winding method is shown in fig. 5;
and 8) putting a vacuum bag into the tank for curing, wherein 2-3 vacuumizing positions are required to be respectively arranged on two sides of the mold due to the large size of the composite material box body, so that the vacuum state of the part is ensured. The mold is large in size and slow in heat conduction, thermocouples need to be buried in the inner cavity and the outer part of the mold, and the curing temperature of the box body needs to be reasonably monitored;
step 9) simultaneously ensuring the air tightness, the interior and the appearance quality of the box body, so that the external pressure of 0.2MPa is selectively added, and the temperature is determined by a selected prepreg resin system;
and step 10), demolding of the composite material box body, wherein a special demolding tool needs to be assisted due to the fact that the box body is large in size. Designing a tool drawing at a small drawing angle end of the tool, wherein the force applying mode of drawing is a pull block; the tool push is designed on the large end of the drawing angle of the tool, and the thrust boosting mode is a jack. Its force application form is shown in FIG. 6;
and 11) after the demolding procedure of the composite material box body, finishing the surface, and entering the next procedure. The forming effect is shown in figure 7.
The present invention is further illustrated by the following specific examples.
Example 1
A box body with the cross section size of 430mm, the wall thickness of 5mm and the length of 4500mm is manufactured by adopting prepreg paving and autoclave molding processes; the specific operation steps are as follows:
1) according to the intensity calculation result, cutting the plain prepreg and the unidirectional prepreg required by the laying by using an automatic cutting machine;
2) cleaning the surface of the metal mold by using a release agent;
3) laying and pasting the prepregs, namely laying and pasting adhesive films after the layers 1 and 3 of prepregs are laid and pasted;
4) after 20 layers of prepregs are laid, appropriate auxiliary materials and an L-shaped auxiliary pressing die at the R-shaped position are placed on the surfaces of the prepregs;
5) winding the demolding ring ribs to assist in demolding of the composite material box body, and winding the ring ribs with the height of about 50mm at two ends of a box body mold respectively;
6) and 2 vacuum pumping positions are required to be respectively arranged at two sides of the mould to ensure the vacuum state of the part because the size of the composite material box body is large. 1 thermocouple is buried in the inner cavity and the outer part of the mold, and the curing temperature of the box body is reasonably monitored;
7) selecting a curing temperature of 125 ℃, and pressurizing at about 60 ℃ under 0.2 MPa;
8) demolding the composite material box body;
9) the surface of the demolded composite box body is flat, 0.025MPa compressed air is filled into the box body, and after 48 hours, the pressure drop is less than 1 percent.
Example 2
A box body with the cross section size of 630mm plus 630mm, the wall thickness of 7mm and the length of 6700mm is manufactured by adopting the prepreg paving and autoclave forming process. The specific operation steps are as follows:
1) according to the intensity calculation result, cutting the plain prepreg and the unidirectional prepreg required by the laying by using an automatic cutting machine;
2) cleaning the surface of the metal mold by using a release agent;
3) laying and pasting the prepregs, namely laying and pasting adhesive films after the layers 1 and 3 of prepregs are laid and pasted;
4) after the 28 layers of prepregs are laid, appropriate auxiliary materials and L-shaped auxiliary pressing dies at the R-shaped positions are placed on the surfaces of the prepregs;
5) winding the demolding ring ribs to assist in demolding of the composite material box body, and winding the ring ribs with the height of about 50mm at two ends of a box body mold respectively;
6) and 3 vacuumizing positions are required to be respectively arranged at two sides of the mould to ensure the vacuum state of the part because the composite material box body is large in size when the vacuum bag is filled into the tank for curing. 2 thermocouples are buried in the inner cavity and the outer part of the mold, and the curing temperature of the box body is reasonably monitored;
7) selecting a curing temperature of 125 ℃, and pressurizing at about 60 ℃ under 0.2 MPa;
8) demolding the composite material box body;
9) the surface of the demolded composite box body is flat, 0.025MPa compressed air is filled into the box body, and after 48 hours, the pressure drop is less than 1 percent.
The 2 box body implementation cases adopting the prepreg paving and autoclave molding process have good air tightness, do not need to carry out repair work, and have high efficiency. High surface quality, no wrinkle, etc., one-step forming, no need of machining, and low cost. The box body has low porosity, good mechanical property and high use reliability.
The present invention is not limited to the above-mentioned embodiments, and based on the technical solutions disclosed in the present invention, those skilled in the art can make some substitutions and modifications to some technical features without creative efforts according to the disclosed technical contents, and these substitutions and modifications are all within the protection scope of the present invention.
Claims (5)
1. A method for forming a square large-size composite material box body with uniform section is characterized by comprising the following steps:
step 1), preparing a prepreg and an adhesive film, taking out the unidirectional prepreg, the plain-weave prepreg and the adhesive film from a refrigeration house, and cooling at room temperature for later use;
step 2), preparing a metal mold, and cleaning the surface of the mold;
step 3) calculating the prepreg paving sequence meeting the use working condition of the box body by using calculation software according to the actual working condition of the box body, wherein the prepreg paving sequence is [45/-45/90/-45/0/45/90/45/0/90] s; cutting the prepreg according to the laying sequence, and cutting prepreg sheets at various angles required by laying by using an automatic cloth cutting machine for standby;
step 4) paving and pasting the prepreg on a mould according to a set paving sequence, wherein the prepreg is paved in an annular butt joint mode, and is paved in the same direction and at the same angle according to the principle of composite material pre-design;
step 5), placing adhesive films, namely placing the adhesive films after the 1 st layer and the 3 rd layer are paved, wherein the adhesive films are full-paved layers with 100 percent of area, the adhesive films are added at the positions close to the inner surface to ensure air tightness, and performing one-time vacuum pumping compaction process on each two layers of prepreg;
step 6), adding a thin-walled L-shaped glass fiber reinforced plastic pressing die to the R corner after all layers are laid;
step 7), winding the demolding ring ribs, and processing the ring ribs at two ends of the box body mold by using a winding process respectively;
step 8) putting a vacuum bag into the tank for curing, arranging 2-3 vacuumizing positions on two sides of the mold respectively to ensure the vacuum state of the part, burying thermocouples in the inner cavity and the outer part of the mold, and monitoring the curing temperature of the box body;
step 9), externally pressurizing, simultaneously ensuring the airtightness, the internal quality and the appearance quality of the box body, and selecting external pressure and temperature determined by the selected prepreg resin system;
step 10), demolding the composite material box body;
and 11) performing a demolding procedure on the composite material box body, and finishing the forming of the box body after the surface is finished.
2. A method for forming a square composite material box with a uniform cross section and a large size as claimed in claim 1, wherein the cooling time in step 1) is more than 6 hours.
3. The method for forming the square-shaped uniform-section large-size composite material box body according to claim 1, wherein the step 2) designs the die to have a draft angle of 2-3 degrees.
4. A method for forming a square constant-section large-size composite material box body according to claim 1, wherein when butt joint is needed in the layering process in the step 4), the distance between two abutted seams is not less than 25mm, and the splicing positions of each layer are staggered.
5. A method for forming a square composite material box with a uniform cross section and a large size as claimed in claim 1, wherein the external pressure in step 9) is 0.1-0.3 MPa.
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| CN201911264391.7A CN110948909B (en) | 2019-12-11 | 2019-12-11 | Forming method of square equal-section large-size composite material box |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112810182A (en) * | 2020-12-29 | 2021-05-18 | 江苏新扬新材料股份有限公司 | Forming method of composite material cylindrical support |
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| CN110948909B (en) | 2021-03-16 |
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