CN112115563B - Integral topology optimization design method for autoclave molding frame type mold - Google Patents
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Abstract
The invention discloses an integral topological optimization design method of an autoclave molding frame type mould, which comprises the following steps of firstly, establishing a three-dimensional geometric solid model of the frame type mould; then creating a finite element model of the three-dimensional geometric solid model, and creating a topological design model of the finite element model; reconstructing a three-dimensional geometric solid model of the frame type mould according to the topological design model; finally, performing performance calculation and analysis comparison on the reconstructed three-dimensional geometric solid model and the original three-dimensional geometric solid model; therefore, on the premise of considering the temperature uniformity and weight reduction requirements of the die, the topological optimization design is developed by taking the improvement of the integral rigidity of the die as a target, the weight reduction effect of the optimally designed die is obvious, the rigidity and the temperature uniformity are greatly improved, and the performance of the die is obviously improved.
Description
Technical Field
The invention relates to the field of topological optimization design, in particular to an integral topological optimization design method of an autoclave molding frame type mold.
Background
The composite material has higher specific strength, specific stiffness, fatigue resistance, corrosion resistance and other excellent performances, has larger and larger occupation ratio in the aircraft structure, and is gradually applied to the large main bearing structure of the aircraft. The autoclave molding is a main manufacturing mode of thermosetting composite materials, in the molding process, the prepreg of the composite materials is paved and attached to the surface of a mold, the deformation of the mold can directly influence the shape and the size precision of a composite material component, and the temperature uniformity of the molded surface of the mold influences the synchronous curing property of the composite materials. The frame type die is used as a key tool for autoclave molding, the supporting structure form of the die becomes more complex along with the continuous increase of the size of a structural component, and if the structural arrangement of the die is unreasonable, the die has overlarge mass and low rigidity, so that the carrying link is difficult; on the other hand, poor mold openness is caused, and the temperature distribution of the mold surface in the molding process is too uneven, so that the synchronous curing degree of the components is reduced. In the actual design process, the frame type structure configuration is often repeatedly adjusted according to experience, so that the design efficiency is low and the cost is high.
At present, the research and analysis aiming at the optimization design method of the autoclave molding frame type mould mainly comprises the following two types:
in document 1 "WangQing, WangLingyun, Zhuweidong, et al. design optimization of models for automatic processes of composite manufacturing [ J ]. Journal of reinforced Plastics and Composites,2017,36(21):1564-1576.DOI: 10.1177/073168441771265", the authors propose a method for optimizing the parameters of a mold substructure that combines a numerical model with a genetic algorithm to improve the synchronicity of mold curing. Five parameters of the length of the frame type mold, the number of support plates in the width direction, the thickness of the support plates, the shape of the vent holes and the distance between the vent holes and the edge of the mold are used as design parameters for optimization design, the standard deviation of the maximum curing degree is improved by 17.21%, but the selection of the design parameters in the text has limitation, and the influence on the static rigidity and the thermal deformation of the mold after the parameters are changed is not considered.
In document 2, "piece-by-piece Cheng. Large-scale composite material structure autoclave process temperature field balance design [ D ]. Harbin Industrial university, 2009", authors verify the reliability of the mold temperature field simulated by using CFX software through experiments, propose that the maximum temperature difference of the mold surface in the autoclave molding process is used as a characteristic value for evaluating the uniformity of the mold temperature field, study the influence rules of the mold surface, the reinforcement thickness, the longitudinal length of the mold, the transverse length of the mold, the shape (circular or square) of the vent hole and the change of the geometric dimension on the mold temperature field, and explore the influence rules of the four process factors of the wind speed, the heating rate, the cooling rate and the mold placing position on the mold temperature field, obtain the influence rules of the design parameters and the process factors on the mold temperature field, and optimize and design the mold with great reference significance, however, the design parameter selection in the text still has limitations, and the influence on the static rigidity and the thermal deformation of the die after changing the parameters is lacked, and the optimization method is not obvious for improving the performance of the die.
In summary, in the existing optimization design of the framework type mold for autoclave molding, the quality evaluation indexes of the mold mainly focus on the synchronicity of the curing degree of the composite material and the temperature uniformity of the molded surface of the mold in the autoclave molding process, the optimization design method mainly includes a mold substructure parameter optimization method and researches on the influence of some basic parameters of the mold on the mold performance, so as to obtain the influence law of some corresponding parameters on the mold, and then the optimal parameters are selected for mold manufacturing.
Disclosure of Invention
The invention aims to provide an integral topological optimization design method of an autoclave molding frame type mold, which develops topological optimization design of a mold structure by aiming at improving integral rigidity of the mold on the premise of considering temperature uniformity and weight reduction requirements of the mold, calculates static rigidity, a temperature field and thermal coupling of the mold structure before and after optimization, and performs comprehensive comparison analysis on the mold performance.
In order to achieve the purpose, the invention provides the following scheme: the invention provides an integral topology optimization design method of an autoclave molding frame type mold, which comprises the following steps:
s1, creating a three-dimensional geometric solid model of the frame type mould;
s2, creating a finite element model of the three-dimensional geometric solid model, and creating a topological optimization design model of the finite element model;
s3, reconstructing the three-dimensional geometric solid model of the frame type mould according to the topological optimization design model;
and S4, performing performance calculation and analysis comparison on the reconstructed three-dimensional geometric solid model and the original three-dimensional geometric solid model.
The top surface of the frame type die is a molded surface, the molded surface is a curved surface, the bottom of the molded surface is a supporting plate, the supporting plate is uniformly distributed in a crossed manner along the length direction and the width direction of the frame type die, rectangular ventilation holes and semicircular temperature equalizing holes are formed in the supporting plate, and four supporting legs are distributed at the bottom of the frame type die.
Preferably, when the topological optimization design is performed on the frame-type mold model in step S2, firstly, the arrangement of the support plates in the model is kept unchanged, the support plates are subjected to materialization design, the materialized support plates are used as a topological optimization design domain, the material distribution of the support plates is designed, then, the model is subjected to mesh division, the model is integrally divided into a plurality of hexahedral mesh units, and meanwhile, the molded surface is divided into shell units; and selecting the minimum compliance of the molded surface as an optimization target, selecting the material volume fraction of the support plate area as constraint, setting the boundary conditions of the mold according to the working condition of the mold, and finally performing topology optimization.
Preferably, performance calculations and analytical comparisons are made in S4 for the reconstituted frame mold and the original frame mold, including calculations of mass, static stiffness, temperature uniformity and thermal deformation in the autoclave:
1) respectively measuring the volumes of the original frame type mould and the optimized frame type mould to obtain the weight reduction condition of the topology optimization mould;
2) respectively carrying out static rigidity calculation on the original frame type mould and the optimized frame type mould: the load borne by the die is simplified and the self gravity is borne, the constraint mode is that one support leg in four support legs is constrained by 6 degrees of freedom, and the other three support legs are constrained by the degrees of freedom in the gravity direction;
3) the simulation calculation of the flow field temperature field in the hot pressing tank is realized: firstly, a pre-processing module is adopted to carry out grid division on a coupling model of a frame type mould and an autoclave, the model is divided into a solid area and a fluid area, the fluid area and the solid area are divided in detail, then the model is established and calculated in the molding process of the autoclave, the calculation of a steady state and a heating stage is respectively carried out in the process, and finally a post-processing platform is used for carrying out the processing of a calculation result to obtain a temperature distribution cloud chart of a molded surface on the mould at the heating end moment;
4) and (2) constructing a thermal coupling calculation model of the frame type mold by using software, calculating thermal deformation and thermal stress of the original frame type mold and the optimized frame type mold respectively, setting the boundary conditions as 6-degree-of-freedom constraint of one support leg, and the remaining three support legs as the gravity direction degree-of-freedom constraint, wherein the applied loads are self gravity and temperature loads of the frame type mold, and obtaining calculation results of the thermal deformation and thermal stress of the frame type mold.
Preferably, the temperature load comprises a frame mould initial state temperature load and a frame mould surface temperature load.
Compared with the prior art, the invention has the following technical effects:
the existing optimization design research aiming at a composite material autoclave molding frame type mold usually focuses on basic parameters of the mold, such as the arrangement form of a support structure of the mold, the thickness of a support plate, the size and the shape of a vent hole, so that the optimization design research has great limitation, the performance of the mold is improved slightly, the design efficiency is low, the cost is high, and the research on the rigidity and the thermal deformation of the mold is lacked.
The topological optimization method for the whole frame type mold, provided by the invention, has the advantages that the support plate in the three-dimensional geometric model of the frame type mold is subjected to materialization design, the materialized support plate is used as a topological optimization design domain, the thickness of the support plate and the size and shape of the vent hole can be changed, the limitation is smaller, the frame type molds with different structures can be obtained and subjected to performance test, and the optimal selection can be used for production, so that technicians in the field can select more various support plate structures, and the topological optimization method has great significance for improving the overall performance of the frame type mold.
In addition, on the premise of considering the temperature uniformity and weight reduction requirements of the die, the topological optimization design is developed by taking the improvement of the integral rigidity of the die as a target, the goals that the weight reduction of the die is 17.2% (the weight reduction of a supporting structure is 36.1%), the maximum static deformation is reduced by 32%, the maximum static stress is reduced by 23.5% and the maximum temperature difference of the die is reduced by 34% at the moment of finishing temperature rise in comparison with the die with the optimized design are achieved, meanwhile, the thermal deformation and the thermal stress are slightly reduced, the weight reduction effect of the optimized die is obvious, the rigidity and the temperature uniformity are greatly improved, and the performance of the die is obviously improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a frame-type mold geometric model;
FIG. 2 is a finite element model of a frame mold;
FIG. 3 is a topological optimization design model of a frame mold;
FIG. 4 is a result of a topology optimization of the frame mold;
FIG. 5 is a reconstructed model of the frame mold;
FIG. 6 is a finite element model of a frame mold temperature field calculation;
FIG. 7 is a frame mold temperature field calculation model;
wherein, 1-profile, 2-support plate, 3-temperature equalizing hole, 4-vent hole, 5-inlet, 6-outlet, 7-solid domain, 8-fluid domain, 9-pipe wall, 10-INVAR alloy, and 11-air with speed of 0.4m/s and pressure of 0.6 MPa.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious 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 derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide an integral topological optimization design method of an autoclave molding frame type mold, which develops topological optimization design of a mold structure by aiming at improving integral rigidity of the mold on the premise of considering temperature uniformity and weight reduction requirements of the mold, calculates static rigidity, a temperature field and thermal coupling of the mold structure before and after optimization, and performs comprehensive comparison analysis on the mold performance.
In order to achieve the purpose, the invention provides the following scheme: the invention provides an integral topology optimization design method of an autoclave molding frame type mold, which comprises the following steps:
s1, creating a three-dimensional geometric solid model of the frame type mould;
s2, creating a finite element model of the three-dimensional geometric solid model, and creating a topological optimization design model of the finite element model;
s3, reconstructing the three-dimensional geometric solid model of the frame type mould according to the topological optimization design model;
and S4, performing performance calculation and analysis comparison on the reconstructed three-dimensional geometric solid model and the original three-dimensional geometric solid model.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1, the top surface of the frame-type mold provided by the invention is a molded surface 1, the molded surface 1 is a curved surface, the bottom of the molded surface 1 is a support plate 2, the support plate 2 is uniformly distributed in a crossed manner along the length direction and the width direction of the frame-type mold, the support plate 2 is provided with a semicircular temperature equalizing hole 3 and a rectangular vent hole 4, and the bottom of the frame-type mold is provided with four support legs.
As shown in fig. 2-3, in the overall topology optimization design method of the autoclave molding frame-type mold provided by the present invention, when the topology optimization design is performed on the frame-type mold model in step S2, the arrangement of the support plates in the model is kept unchanged, the support plates are designed in an materialized manner, the materialized support plates are used as a topology optimization design domain to design the material distribution of the support plates, then the model is subjected to grid division, the model is divided into a plurality of hexahedral grid cells as a whole, and the molded surface is divided into shell cells.
And when a topological optimization design model of the mold is constructed, determining an optimization target and constraint according to the working environment of the mold and the characteristics of the mold. Because the composite material is directly contacted with the upper molded surface of the mold, the minimum compliance of the upper molded surface of the mold is selected as an optimization target; in order to reduce the weight of the die and improve the smoothness, the volume fraction of the material in the support plate area is selected as constraint; and then setting boundary conditions and loads of the die according to the working condition of the die, constraining one of four support legs of the die in six degrees of freedom, constraining the other three support legs in the direction of gravity, and uniformly distributing pressure on the die under the action of self gravity and the molded surface.
According to the overall topological optimization design method of the autoclave molding frame type mold, the design domain structure shown in the figure 4 is obtained after the step S3 topological optimization, then the optimization result and the feasibility of the actual production manufacturing process are considered, meanwhile, the mold smoothness is improved, the mold is reconstructed by taking the optimization result as reference, and the mold supporting structure shown in the figure 5 is obtained.
The overall topology optimization design method of the autoclave molding frame type mold provided by the invention comprehensively compares the performances of the original mold and the optimized mold in step S4, and comprises the calculation of the mass, the static rigidity, the temperature uniformity in the autoclave and the thermal deformation of the mold.
1) The method has the advantages that the sizes of the original die and the optimized die are respectively measured by using Solidworks software, so that the weight reduction condition of the topology optimization die is further obtained, the overall weight reduction of the die is realized by 17.2%, the weight reduction of the supporting structure is 36.1%, and the weight reduction effect is obvious;
2) static rigidity calculation is respectively carried out on the two dies by using ABAQUS software, and the load borne by the dies is simplified as follows: the mould bears the self gravity (the mass of the prepreg paving layer and the auxiliary material on the molded surface is small and can be ignored), the constraint mode is that one support leg is constrained in six degrees of freedom, the other 3 support legs are constrained in the gravity direction, the static rigidity calculation is carried out, and the performance of the mould is compared according to the static deformation and the stress of the mould;
3) simulation calculation of a flow field temperature field in an autoclave is realized through commercial finite element simulation software ANSYS, firstly, a pretreatment module ICEM-CFD is adopted to carry out mesh division on a coupling model of a die and the autoclave, the model is divided into an entity area and a fluid area, and the fluid area and the entity area are divided in detail, so that the quality and the calculation precision of a mesh are ensured, as shown in FIG. 6; then, establishing and calculating an autoclave molding process model by using a CFX module, as shown in FIG. 7, wherein the calculation of a steady state and a temperature rise stage needs to be performed in the process respectively; finally, Post-processing the calculation result by using a Post-processing platform CFX-Post to obtain a temperature distribution cloud chart of the upper molded surface of the mold at the heating end time, and measuring the temperature uniformity of the mold in the hot pressing tank according to the maximum temperature difference of the molded surface of the mold at the heating end time;
4) a frame type mold thermal coupling calculation model is constructed by using ABAQUS software, thermal deformation and thermal stress are calculated for two molds respectively, the boundary conditions of the molds are set as 6-degree-of-freedom constraint of one support leg, the other three support legs constrain displacement in the gravity direction, the applied loads are the self gravity and the temperature loads of the molds, the temperature loads comprise the temperature loads (predefined temperature field) of the initial state of the molds and the temperature loads of the surfaces of the molds, the calculation results of the thermal deformation and the thermal stress of the molds are obtained, and the performances of the molds are compared according to the magnitudes of the deformation and the stress.
The adaptation according to the actual needs is within the scope of the invention.
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. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Claims (3)
1. The integral topological optimization design method of the autoclave molding frame type mold is characterized by comprising the following steps of:
s1, creating a three-dimensional geometric solid model of the frame type mould;
s2, creating a finite element model of the three-dimensional geometric solid model, and creating a topological optimization design model of the finite element model;
s3, reconstructing the three-dimensional geometric solid model of the frame type mould according to the topological optimization design model;
s4, performing performance calculation and analysis comparison on the reconstructed three-dimensional geometric solid model and the original three-dimensional geometric solid model;
the top surface of the frame type mold is a molded surface, the molded surface is a curved surface, the bottom of the molded surface is a support plate, the support plates are uniformly distributed in a crossed manner along the length direction and the width direction of the frame type mold, rectangular vent holes and semicircular temperature equalizing holes are formed in the support plates, and four support legs are distributed at the bottom of the frame type mold;
performance calculations and analytical comparisons were made in S4 for the reconfigured frame mold and the original frame mold, including calculations of mass, static stiffness, temperature uniformity in autoclave and thermal distortion of the frame mold:
1) respectively measuring the volumes of the original frame type mould and the optimized frame type mould to obtain the weight reduction condition of the topology optimization mould;
2) respectively carrying out static rigidity calculation on the original frame type mould and the optimized frame type mould: the load borne by the die is simplified and the self gravity is borne, the constraint mode is that one support leg in four support legs is constrained by 6 degrees of freedom, and the other three support legs are constrained by the degrees of freedom in the gravity direction;
3) the simulation calculation of the flow field temperature field in the hot pressing tank is realized: firstly, a pre-processing module is adopted to carry out grid division on a coupling model of a frame type mould and an autoclave, the model is divided into a solid area and a fluid area, the fluid area and the solid area are divided in detail, then the model is established and calculated in the molding process of the autoclave, the calculation of a steady state and a heating stage is respectively carried out in the process, and finally a post-processing platform is used for carrying out the processing of a calculation result to obtain a temperature distribution cloud chart of a molded surface on the mould at the heating end moment;
4) and (2) constructing a thermal coupling calculation model of the frame type mold by using software, calculating thermal deformation and thermal stress of the original frame type mold and the optimized frame type mold respectively, setting the boundary conditions as 6-degree-of-freedom constraint of one support leg, and the remaining three support legs as the gravity direction degree-of-freedom constraint, wherein the applied loads are self gravity and temperature loads of the frame type mold, and obtaining calculation results of the thermal deformation and thermal stress of the frame type mold.
2. The method as claimed in claim 1, wherein when the topology optimization design is performed on the frame-type mold model in step S2, the arrangement of the supporting plates in the model is kept unchanged, the supporting plates are designed in an materialized manner, the materialized supporting plates are used as the topology optimization design domain to design the material distribution of the supporting plates, then the model is subjected to grid division to divide the model into a plurality of hexahedral grid cells as a whole, and the molded surface is divided into shell cells; and selecting the minimum compliance of the molded surface as an optimization target, selecting the material volume fraction of the support plate area as constraint, setting the boundary conditions of the mold according to the working condition of the mold, and finally performing topology optimization.
3. The method of claim 1, wherein the temperature loads comprise frame mold initial state temperature loads and frame mold surface temperature loads.
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