CN112297462A - Manufacturing method of rocket engine full composite material shell - Google Patents
Manufacturing method of rocket engine full composite material shell Download PDFInfo
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- CN112297462A CN112297462A CN202010909011.7A CN202010909011A CN112297462A CN 112297462 A CN112297462 A CN 112297462A CN 202010909011 A CN202010909011 A CN 202010909011A CN 112297462 A CN112297462 A CN 112297462A
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Images
Classifications
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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
-
- 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
-
- 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
-
- 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
- B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3097—Cosmonautical vehicles; Rockets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/748—Machines or parts thereof not otherwise provided for
- B29L2031/749—Motors
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention discloses a method for manufacturing a rocket engine full composite material shell, which comprises the following steps: 1) manufacturing a joint; 2) manufacturing a core mold middle section; 3) manufacturing a skirt; 4) manufacturing a heat insulation core mold: manufacturing a rubber layer on the end face, close to the core mold, of the joint manufactured in the step 1), mounting the joint and the end socket rubber layer at two ends of the core mold, laying a heat insulation layer on the surface of the middle section of the core mold by adopting a laying and pasting process, and vacuumizing and pre-compacting after laying to obtain the heat insulation core mold; 5) fiber winding: winding the carbon fiber yarns impregnated with the resin on the heat insulation core mold in a spiral inclined winding matched mode in a circumferential winding mode, wherein glue solution on the surface of the winding layer needs to be scraped in the winding process, after the fiber winding is finished, sleeving skirts manufactured in the step 3) at two ends of the core mold wound with the fibers, and performing circumferential winding after the skirts are fixed; 6) curing; 7) demoulding, and has the characteristics of obvious weight reduction effect, high reliability, low cost and high bursting pressure.
Description
Technical Field
The invention relates to a rocket engine, in particular to a rocket engine shell.
Background
The composite material has the characteristics of high specific strength, high specific modulus, stable size, strong designability and the like, becomes one of the most important aerospace structural materials after aluminum alloy, titanium alloy and steel, and is widely applied to the aerospace field.
With the rapid development of aerospace industry, the weight of structural devices is more stringent. The light and high-strength composite material has important significance for reducing the weight of an engine, improving the performance of an aircraft and reducing the launching cost.
In the 60's of the 20 th century, composite engine casings were used on American rocket engines, and then, a great deal of research work was carried out in all countries, most of the rocket engines at present adopt carbon fiber wound epoxy resin composite materials, but parts such as flange joints of the rocket engines are still made of metal materials, so that the weight reduction has further improved space.
Disclosure of Invention
The invention aims to provide a method for manufacturing a rocket engine all-composite shell, which has the characteristics of obvious weight reduction effect, high reliability, low cost and high bursting pressure.
The purpose of the invention is realized as follows: a manufacturing method of a rocket engine full composite material shell comprises the following steps:
1) manufacturing a joint: manufacturing a joint by using a carbon fiber prepreg through a layering process, and heating, pressurizing and curing after layering to obtain the joint for later use;
2) manufacturing a core mold middle section;
3) manufacturing a skirt: manufacturing a skirt by adopting a carbon fiber prepreg through a layering process, and heating, pressurizing and curing to obtain the skirt for later use after layering is finished;
4) manufacturing a heat insulation core mold: wrapping a layer of demolding cloth on the surface of the middle section of the core mold prepared in the step 2), forming an end socket rubber layer on the joint prepared in the step 1) close to the end face of the core mold through paving and molding processes, mounting the joint and the end socket rubber layer at two ends of the core mold, paving a heat insulating layer on the surface of the middle section of the core mold through a paving process, and vacuumizing and pre-compacting after paving to obtain the heat insulating core mold;
5) fiber winding: winding the carbon fiber yarn impregnated with the resin on the heat insulation core mold in a spiral inclined winding matched manner in a circumferential winding mode, keeping the tension of the carbon fiber yarn in a set range in the winding process, scraping glue solution on the surface of the winding layer in the winding process, sleeving the skirts manufactured in the step 3) at two ends of the core mold wound with the fibers after the fibers are wound, and performing circumferential winding after the skirts are fixed;
6) and (3) curing: after winding is finished, rotating the composite material shell on a winding machine for a period of time, then putting the composite material shell into an oven for heating and curing, discharging the composite material shell out of the oven after cooling, and keeping the composite material shell rotating in the curing process;
7) demolding: and after curing and forming, flushing water into the shell to dissolve the soluble core mold, demolding, cleaning the interior of the shell, and drying residual moisture to obtain the full-composite shell.
As a further limitation of the present invention, the specific method for manufacturing the rubber layer in step 4) is as follows: and sequentially paving and pasting a first rubber layer, a second rubber layer and a third rubber layer in the lower die from bottom to top, putting the joint in the process of paving and pasting the first rubber layer, and putting the woven layer between the process of paving and pasting the second rubber layer and the third rubber layer to obtain the heat insulation joint.
As a further limitation of the invention, the surface of the mold for laying the heat-insulating rubber layer is treated by a polytetrafluoroethylene sintering process before laying.
As a further limitation of the present invention, the paving process of the first rubber layer specifically comprises: firstly, brushing an adhesive on the surface of a lower die, brushing a rubber sheet with the adhesive, paving and pasting the rubber sheet on the corresponding position of the die after drying, compacting the surface of the rubber sheet, brushing the adhesive on a joint and the bonding area of the joint and the rubber sheet, putting the joint into the lower die after drying, compacting the joint, brushing the rubber sheet with the adhesive, and paving and pasting the rubber sheet on the surface of the joint after drying, and compacting the surface of the joint.
As a further limitation of the present invention, the process of placing the braid is specifically as follows: and coating adhesive on the areas bonded with the second rubber layer and the third rubber layer on the surface of the woven layer, paving an adhesive film on the surface after air drying, coating the adhesive on the surface of the adhesive film and the surface of the rubber of the second rubber layer, and adhering and compacting after air drying.
As a further limitation of the invention, the glue solution on the surface of the winding layer is scraped in the step 5); and scraping the glue once every other time, controlling the surface of the winding layer to have no obvious glue residue, simultaneously weighing and detecting the scraped glue solution, and winding the waste gas if the viscosity exceeds a set range of 0.35-1.0 Pa.s.
Compared with the prior art, the invention has the beneficial effects that: the invention adopts the full composite material shell to reduce the weight and improve the container efficiency; the heat insulation layer is paved, and the rubber layer is processed on the inner side of the joint, so that the heat insulation performance of the shell is greatly improved, and the interlayer strength and the pressure resistance of the shell can be improved while the heat insulation performance of the shell is ensured by the paving process of the rubber layer; the joint is laid after being installed, so that the reliability of bonding between the joint and the heat insulating layer is guaranteed, and the influence of the traditional joint compression molding pressure on the joint is avoided.
Drawings
FIG. 1 is a full composite shell made according to the present invention.
FIG. 2 is a schematic view of a composite material joint structure according to the present invention.
FIG. 3 is a flow chart of the present invention.
FIG. 4 is a flow chart of making a joint according to the present invention.
Fig. 5 is a schematic structural view of a forming mold for laying a rubber layer of the composite material joint according to the present invention.
FIG. 6 is a schematic diagram of the rubber layer laying numbering sequence of the composite material joint of the present invention.
The composite material heat insulation joint comprises a composite material heat insulation joint 1, a composite material joint 11, an edge portion 11a, an ablation-resistant woven layer 12, a heat insulation rubber layer 13, a covered edge 13a, a heat insulation layer 2, a composite material shell 3, a composite material skirt 4, carbon cloth 5 and a carbon fiber layer 6.
Detailed Description
The following sets forth specific embodiments to further illustrate the invention.
As shown in fig. 1-2, the engine casing made of a full composite material by the method of the present invention comprises composite material heat insulation joints 1 arranged at two ends inside a composite material casing 3, a heat insulation layer 2 is arranged on the inner circumference of the composite material casing 3, composite material skirts 4 are sleeved on two ends outside the composite material casing 3, a carbon cloth 5 is arranged at the seam between the composite material skirts 4 and the composite material casing 3, the carbon cloth 5 is a T800 plain carbon cloth 5 with a width of 200mm, the outer circumferences of the composite material skirts 4 and the carbon cloth 5 are wrapped with carbon fiber layers 6, the composite material heat insulation joints 1 comprise composite material joints 11, the composite material joints 11 are paved with heat insulation rubber layers 13 close to the end faces and the inner circumferential faces inside the casing, ablation resistant braided layers 12 are embedded in the heat insulation rubber layers 13, the outer circumferential edge of the composite material joints 11 extends outwards along the radial direction to form, the heat insulation rubber layer 13 extends to the top surface of the edge part 11a, the top surface of the heat insulation rubber layer 13 is processed into a plane structure, the periphery of the heat insulation rubber layer extends upwards to form a covered edge 13a, and the top surface and the inner peripheral surface of the heat insulation rubber layer 13 are transited through arc surfaces; the rubber is ethylene propylene diene monomer.
The present invention will be described in detail below with reference to specific manufacturing methods:
a method of manufacturing a rocket motor full composite shell as shown in fig. 3, comprising the steps of:
(1) preparing a mould: preparing a die for manufacturing the connector and the skirt;
a. cleaning a mold: cleaning residues on a mold forming surface and the like by using tools such as a blade and the like to avoid scratching the mold forming surface, then soaking a small amount of acetone in a clean cloth tape to wipe the mold, cleaning residues which affect a product such as a small amount of residual glue and the like, and airing;
b. firstly, a lower die plate, an inner die ring and an outer die ring of the half die are installed, and then an upper die plate of the die is installed after layering is completed.
(2) Laying a joint:
a. selecting a T800 carbon fiber unidirectional prepreg and a carbon fiber plain prepreg;
b. blanking according to the designed shape and quantity of the expanded drawings, and numbering;
c. carrying out layering operation on a mould according to a designed layering process, wherein the laying is 80%, and the whole package of layering is 20%;
d. dividing the joint into 4 areas, laying whole-package areas II and I firstly as shown in FIG. 4, wherein the area I is unfolded outwards firstly, then laying the area III, then laying the area IV, and finally turning the area I onto the laying area III. The region III is a side cladding layer, and the regions II and I are whole cladding layers; firstly, paving a whole cladding, and then paving a side cladding, wherein the two are crossed and layered; after the first layer of the whole cladding layer is paved, vacuumizing for 5min for one time, and compacting the corners;
e. paving the area III and then paving the area IV; when laying the IV, after reaching 4/5 with high height, turning over the area I, cross-laying with the IV, and staggering the upper and lower layers to form a butt joint; after the flanging is finished, 2 layers of plain cloth are laid on the outermost surface;
f. in the paving process, air bubbles are driven out and compacted by a driving plate, and the time is 4 hours when every 8 layers are vacuumized, exhausted and compacted;
g. and (4) after a release agent is applied to the upper cover plate, die assembly is carried out, and the die assembly is ensured to be in place.
(3) Joint curing:
a. confirming whether the press can normally run or not, and recording (time, pressure and heating point) for 20 minutes;
b. hoisting the parts to the platform of the hot press, correctly placing the parts, and respectively placing the parts on the upper surface and the lower surface of the parts
A metal plate to ensure the parts to be heated uniformly;
c. checking the state of the thermocouple, installing the thermocouple, placing one thermocouple at each of two sides, and confirming that the installation is firm;
d. putting the tool into a press, setting the heating temperature to be about 70 ℃, keeping the temperature for 2 hours, and keeping the pressure to be 57
Recording the curing start time in tons; record 20 minutes (time, pressure, heat point); measuring the temperature by using a temperature measuring gun to ensure that the temperature of each part is uniform;
e. when the temperature of the thermocouple reaches 140 ℃, pressurization is started, the pressure reaches 200 tons, and the heat preservation is carried out for 0.5 hour
The temperature is kept for 200 tons for 20 minutes and is recorded once (time, pressure and heating point), the temperature is heated to about 160 ℃, the temperature is kept for 3 hours, and the initial time of the temperature keeping is recorded. Measuring the temperature by using a temperature measuring gun to ensure that the temperature of each part is uniform;
f, after the heat preservation at about 160 ℃, setting the heating temperature to about 180 ℃, and preserving the heat for 1.5 hours and keeping the pressure at 200 tons; 20 minutes recording (time, pressure, heat point) record the incubation start time. Measuring the temperature by using a temperature measuring gun to ensure that the temperature of each part is uniform;
finishing the heat preservation at about h.180 ℃, and preserving the heat for 1.5 hours after the temperature is 180 +/-5 ℃; record 20 minutes (time, pressure, heat point); record the incubation start time. Measuring the temperature by using a temperature measuring gun to ensure that the temperature of each part is uniform;
i. closing the heating device, and naturally cooling to room temperature; the thermocouple can be removed when the temperature is lower than 60 ℃;
j. and machining the demoulded joint blank to the required size according to the design drawing requirements to obtain the composite material joint for later use.
(4) Manufacturing a core mold middle section:
the middle section of the core mould adopts a sand core mould process, the sand core mould is cast by a special mould for the special sand core mould, the mould is divided into three halves, and the external diameter size of the sand core mould is ensured by the adding precision of a mould machine; the sand core mold is manufactured by adopting segmented prefabrication molding; mixing the foundry sand with a polyvinyl alcohol aqueous solution according to the proportion of 5: 1, uniformly stirring, pouring into a metal mold, and casting and molding; drying at about 100 ℃, then disassembling the casting mold for sectioning, and taking out the sand core mold from the mold; the surface treatment process of the core mold comprises the following steps: firstly, polishing the surface of an assembled mandrel by using sand paper to remove excess materials; airing; the size of the shell sand core mold is detected, and the outer molded surface of the shell core mold is required to meet the size requirement of the inner molded surface of the shell rubber.
(5) Preparation of skirt mold: the mould forming surface is cleaned by tools such as a blade and the like, the mould forming surface is prevented from being scratched, then the mould is wiped by using a small amount of acetone soaked in a clean cloth tape, and residues which affect products such as a small amount of residual glue are cleaned and dried.
(6) Manufacturing the skirt:
a. selecting T800 epoxy resin unidirectional prepreg, carrying out thawing treatment on the prepreg taken out from a refrigeration house, and cleaning a die;
b. cutting the prepreg by the fabric cutting machine according to the designed shape, angle and quantity, and numbering each material sheet;
c. according to a process file, carrying out layering operation on a corresponding area of the die, and carrying out vacuum compaction and glue absorption treatment once every 5 layers or so;
d. after the layering is finished, carrying out curing molding in an autoclave; the curing system is as follows: heating to 130 ℃ at the speed of 2 ℃/min, preserving heat for 1 hour, heating to 150 ℃ at the speed of 2 ℃/min, preserving heat for 1 hour, heating to 180 ℃ at the speed of 2 ℃/min, preserving heat for 1 hour, heating to 150 ℃ at the speed of 2 ℃/min, preserving heat for 4 hours, naturally cooling to below 60 ℃, and demolding; the molding pressure is 0.6 MPa;
e. after the solidification is finished, performing deburring treatment on the product, and mechanically processing the profile to a corresponding size;
f. machining corresponding hole positions of the demolded skirt according to the requirements of a drawing for later use;
(7) wrapping a layer of polytetrafluoroethylene release cloth on the middle section of the core mold, and respectively brushing a layer of release agent on the surfaces of the front section and the rear section of the core mold so as to facilitate the separation of the middle section of the core mold from the rubber heat insulation layer of the joint;
(8) the heat-resistant treatment and installation of the composite material joint are carried out by firstly forming an end socket rubber layer on the end surface of the composite material joint close to the core mould through paving and mould pressing processes, and then fixing the composite material joint at the two ends of the core mould, wherein the specific process comprises the following steps:
a. preparing raw materials and a mould: cutting the rubber sheet to be paved by using a cutting machine, chamfering, and putting a forming die at the same time, wherein the forming die comprises the following parts as shown in figure 5: (1) the upper die is used for forming the back surface of the joint and providing a stress surface for the press; (2) the lower die is used for fixing the composite material joint and providing a paving surface for rubber paving; (3) the guide posts are used for the upper die and the lower die, and pin holes are designed due to the positioning requirement;
b. paving: before paving and pasting, using polytetrafluoroethylene for sintering to treat the surface of a mold, paving and pasting a first rubber layer, a second rubber layer and a third rubber layer in a lower mold from bottom to top in sequence, putting a joint in the process of paving and pasting the first rubber layer, putting a woven layer between the process of paving and pasting the second rubber layer and the third rubber layer, paving and pasting one layer at each end in the paving and pasting process, detecting the surface state of the rubber, using a driving plate to compact all areas, if not, using a steel needle to puncture and compact residual bubbles, if not, injecting a proper amount of glue into a needle cylinder, airing for about 5min, and then compacting; and when paving, overlapping according to the direction of the downdraft, the circumferential overlapping seams of each layer cannot be overlapped, the positions are staggered by more than 2mm, the overlapping seams cannot be larger than 25mm, the overlapped parts need to be chamfered by bevel edges, the thickness of the product is ensured to be consistent, so that the manufacturing requirement of the heat insulation layer structure is met, meanwhile, heat insulation material fragments and other redundancies cannot exist among the material sheets in the paving process, and the redundancies are processed according to the QJ2850 standard; the insulation manufacturing environment requires that the field temperature is 24 +/-10) DEG C, the relative humidity is less than or equal to 75%, parameters such as the gluing time, the airing time, the heat insulation layer pasting time and the like of each heat insulation layer are recorded in the paving and pasting process, and the thickness detection, the gluing amount and the total weight of the heat insulation layer and the glue solution weight are recorded after the heat insulation layer is pasted;
as shown in fig. 6, the specific steps of paving are as follows:
b, paving and pasting the first rubber layer (the paving and pasting sequence is PH-01-02): brushing a small amount of adhesive on the surface of a lower die mould, brushing the rubber sheet of the first rubber layer, airing for about 5min, paving and sticking the lower die mould on the surface of the mould, compacting, brushing the adhesive on the joint in the bonding area with the rubber sheet, putting the joint into the lower die and compacting after airing, brushing the rubber sheet with the adhesive, paving and sticking the lower die mould on the surface of the joint and compacting after airing; brushing glue at the next position after each position is paved, paving and compacting, and recording weight information;
b, paving and pasting a second rubber layer (the paving and pasting sequence is PH-02-01-PH-02-04): brushing a layer of adhesive on the back side of the joint for compaction, paving and pasting the rubber sheets of the second rubber layer according to the serial number sequence, compacting to form a relatively flat binding surface, and recording weight information;
b-c, placing the braided body, polishing the braided body according to the layer schematic diagram, paving a layer of adhesive film on the corresponding bonding area of the first rubber layer to enable the braided body to be interfered with rubber, and sequentially brushing an adhesive on the surface of the corresponding bonding area on the braided body to prevent interference; air drying for 10min, and sticking a glue film on the surface;
b-d, paving and pasting a third rubber layer (the paving and pasting sequence is PH-03-01-PH-03-17), coating adhesive on an adhesive film on the upper surface of the woven body, and paving and pasting rubber sheets of the third rubber layer according to the numbering sequence to enable the top layer of the third rubber layer to be a plane;
c, die assembly: and cleaning 2 positioning pins matched with the tool and pin holes of the tool by using acetone. Hoisting the upper die by using a travelling crane, loading the positioning pin into the lower die, and aligning 2 pin holes to enable the upper die and the lower die to be matched; after the upper die is clamped into the positioning pin, knocking the upper die by a copper bar to be firmly attached;
d. and (3) curing: heating and curing the hot pressing by using a hot press, controlling heating parameters, checking a heating device and a pressurizing device, and determining whether the hot pressing can normally operate; removing the excess on the platform, and hoisting the parts to the middle of the platform of the hot press; checking the state of the thermocouples, installing 3-4 thermocouples in the temperature measuring holes, and fixing by using putty strips; the curing parameters are specifically as follows: the first stage is as follows: heating at a rate of 30 ℃/h at room temperature of-90 ℃, keeping the temperature for 1h, and pressurizing; and a second stage: the heating rate is 20 ℃/h, the temperature is 90-125 ℃, and the temperature is kept for 2 h; and a third stage: the heating rate is 10 ℃/h, the temperature is 125-150 ℃, and the temperature is kept for 3 h; a fourth stage: the temperature reduction rate is 30 ℃/h, the temperature is 150-60 ℃, the pressure is relieved, and the steel plate is taken out of the furnace;
e. demolding: after demolding, checking whether the curing mold is matched in place, if not, measuring the thickness difference of the periphery, marking and recording; pulling out the positioning pin by using a pin puller, slowly lifting the upper die by using a travelling crane, and checking whether the product is adhered to the surfaces of the upper die and the lower die at the same time; if the bonding is carried out, a scraper knife (the knife edge is wrapped by a piece of demoulding cloth) is used for separation.
The composite material heat-insulating seal head is formed by an ablation-resistant woven layer, a composite material joint and a heat-insulating rubber layer, so that the heat resistance of the composite material heat-insulating seal head is greatly improved, the composite material heat-insulating seal head can be ablated for about 3min at the temperature of 2000-3000 ℃, and the use of a solid engine shell combustion chamber can be met; meanwhile, the end socket made by the invention has lighter mass than the traditional end socket, and can improve the flight propulsion efficiency of the engine shell.
(9) Manufacturing a heat insulating layer:
a. blanking: the heat insulation layer material sheet is designed and cut according to the process requirement, and the thickness is respectively as follows: 1mm, 1.5mm, 2mm, 3 mm;
b. and (3) thickness measurement: airing the air-conditioning room for 3 hours, uniformly taking 5 points at the edge, and taking an average value; the material sheets are overlapped by adopting an oblique notch of less than 30 degrees; delta is not less than 1mm, no chamfering is needed, delta is not less than 1.5 and not more than 2.5mm, the chamfering thickness is not less than 3.5mm, delta =3mm, and the width is not less than 5.2 mm;
c. preparing a material sheet: before the material sheet is paved and pasted, J-1 adhesive is coated on the pasting surface (comprising the material sheet pasting surface and the bottom layer surface), the material sheet is pasted within 3-10 min after coating, and the material sheet is pressed by hands to be solid, and bubbles are removed by needling;
d. paving a heat insulating layer: cleaning the bonding surface of the material sheet (shell) by using ethyl acetate; cleaning with ethyl acetate, brushing the adhesive, and respectively air-drying for 5-10 min; the material sheet is laid and pasted according to the process design (pasting position and sequence); the material sheets are lapped by 5mm-15mm and bonded by airflow; checking and removing bubbles in time in the process of bonding the material sheets; when the multiple layers of material sheets are bonded, the annular overlapping edges between the layers are staggered by not less than 100 mm;
e. the curing temperature takes into account the vulcanization point of the heat insulating layer; a temperature control route of room temperature-self-elevating at the temperature of 110 +/-5 ℃, heat preservation for 2 h-controlled elevating at the temperature of 15 ℃/h to 165 +/-5 ℃ and heat preservation for 1 h-controlled lowering at the temperature of 15 ℃/h to 100 +/-5 ℃ and self-lowering at the temperature of-50 ℃ is adopted.
(10) And (3) sequentially passing the T800 continuous carbon fibers through a yarn outlet and a glue dipping roller according to the yarn threading sequence of a winding machine, and soaking the T800 continuous carbon fibers in the previously prepared high-temperature-resistant epoxy resin glue at the temperature of 30-40 ℃ for about 2 seconds.
(11) Winding continuous carbon fibers, namely winding the rubber heat insulation layer in the step (9) by using the continuous carbon fibers infiltrated in the step (10), wherein the winding is carried out in a spiral inclined and annular alternate winding mode, and the winding tension is controlled during winding; the specific winding process is as follows:
the shell is wound by a wet method, and the linear type is spiral winding and hoop winding. Performing linear debugging on the shell on the rubber joint of the heat insulation layer, and starting formal winding after the linear meets the process design requirement; the shell is wound by adopting T800/6k domestic fiber to soak medium-temperature epoxy resin, the number of yarn sheets is 6, the spreading width of the yarn sheets is 15mm, the number of longitudinal winding layers is 6, the number of circumferential winding layers is 6, the fiber volume content is controlled to be about 60 percent, and the gel content is mainly controlled by the tension of the winding machine for winding the fiber; wherein the thickness of the yarn sheet is 0.1mm, and the thickness of the winding layer of the shell column section is 2 mm; for guaranteeing casing fibre volume content and fibre performance coefficient simultaneously, fibrous degree of wear of minimize, control casing successive layer winding tension, 2 vertical winding layers of casing and 2 ring winding layers go on in turn, totally 3 winding circulations, and the tension gradiometer is shown in the following table.
The temperature (24 +/-10) DEG C and the relative humidity of the cylinder winding environment are required, the temperature and the humidity of each day are recorded every 3 h;
in order to control the volume content of the fibers to be 59 +/-1%, the content of glue solution is controlled, and the glue solution overflowing from the front joint, the rear joint and the column section is manually scraped during winding;
before winding, the fiber tension is adjusted, the fiber tension is measured by a tensioner, and the tension control mechanism is adjusted to achieve the tension precision specified by a file. And setting linear winding according to design requirements, adjusting a glue dipping device at any time, controlling the glue amount of the fiber tape, scraping redundant glue on the surface of a product at any time during winding, and observing the yarn arrangement condition, wherein if yarn sheets slide, overlap or have gaps and the like, the machine should be stopped in time. And (3) continuously adding new glue solution in the winding process, removing yarn wool on the rubber roll and the glue solution dripped on winding equipment, keeping the cleanness and sanitation of the whole produced wire, and realizing civilized production.
(12) And (3) after winding is finished, respectively installing the front skirt and the rear skirt on a front upper skirt tool and a rear upper skirt tool, installing the skirt manufactured in the step (6) on the product manufactured in the winding step (11) by using the upper skirt tools, and positioning and fixing according to related positioning relation.
(13) Continuously winding the product provided with the upper skirt in the circumferential direction; after the upper skirt is successfully wound, T800 plain carbon cloth with the width of 200mm is wound at the seam of the front skirt and the rear skirt, then 8 layers of annular continuous T800 carbon fibers are wound, 5 yarn bundles are used, and the winding tension is 40N/strand until the yarn bundles are wound to the designed thickness.
(14) After the winding process is finished, curing the composite material shell; sending the product into a curing furnace, connecting the mandrel with a mechanical rotating device, and driving the mandrel to rotate at the speed of 0.5 revolution per minute; normal pressure heating and curing are adopted in the curing process, the shell winding layer and the heat insulation rubber layer are cured together, and the curing system is as follows: 80 ℃ at 2h, 150/4 h.
(15) After the shell curing process is finished, as the soluble sand mold is used, the sand core mold part needs to be washed away by water, and hot water high-pressure washing is usually adopted for convenience of demolding; after the solidified shell is cooled to room temperature, the locking nuts at the two ends are loosened, and the mandrel is pulled out; then dissolving the sand core by using water; and (4) washing the sand core, and drying at 80 ℃ for 8h to obtain the full-composite engine shell.
The total composite material shell is reduced by 4 kilograms compared with a metal joint composite material shell, the blasting pressure meets the design requirement, the damage form is damaged from the ring winding position, the composite material joint is not damaged, the ground test meets the requirement, and the heat resistance meets the requirement.
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 (6)
1. A manufacturing method of a rocket engine full composite material shell is characterized by comprising the following steps:
1) manufacturing a joint: manufacturing a joint by using a carbon fiber prepreg through a layering process, and heating, pressurizing and curing after layering to obtain the joint for later use;
2) manufacturing a core mold middle section;
3) manufacturing a skirt: manufacturing a skirt by adopting a carbon fiber prepreg through a layering process, and heating, pressurizing and curing to obtain the skirt for later use after layering is finished;
4) manufacturing a heat insulation core mold: wrapping a layer of demolding cloth on the surface of the middle section of the core mold prepared in the step 2), forming an end socket rubber layer on the joint prepared in the step 1) close to the end face of the core mold through paving and molding processes, mounting the joint and the end socket rubber layer at two ends of the core mold, paving a heat insulating layer on the surface of the middle section of the core mold through a paving process, and vacuumizing and pre-compacting after paving to obtain the heat insulating core mold;
5) fiber winding: winding the carbon fiber yarn impregnated with the resin on the heat insulation core mold in a spiral inclined winding matched manner in a circumferential winding mode, keeping the tension of the carbon fiber yarn in a set range in the winding process, scraping glue solution on the surface of the winding layer in the winding process, sleeving the skirts manufactured in the step 3) at two ends of the core mold wound with the fibers after the fibers are wound, and performing circumferential winding after the skirts are fixed;
6) and (3) curing: after winding is finished, rotating the composite material shell on a winding machine for a period of time, then putting the composite material shell into an oven for heating and curing, discharging the composite material shell out of the oven after cooling, and keeping the composite material shell rotating in the curing process;
7) demolding: and after curing and forming, flushing water into the shell to dissolve the soluble core mold, demolding, cleaning the interior of the shell, and drying residual moisture to obtain the full-composite shell.
2. A method for manufacturing a rocket engine all-composite shell according to claim 1, wherein the specific method for manufacturing the rubber layer in step 4) is as follows: and sequentially paving and pasting a first rubber layer, a second rubber layer and a third rubber layer in the lower die from bottom to top, putting the joint in the process of paving and pasting the first rubber layer, and putting an ablation-resistant woven layer between the process of paving and pasting the second rubber layer and the third rubber layer to obtain the heat-insulating joint.
3. A method of manufacturing a rocket motor full composite shell according to claim 2, wherein the surface of the mold for the thermal insulation rubber layer is treated by polytetrafluoroethylene sintering before the coating.
4. The method for manufacturing the rocket engine full composite shell according to claim 2, wherein the paving process of the first rubber layer specifically comprises the following steps: firstly, brushing an adhesive on the surface of a lower die, brushing a rubber sheet with the adhesive, paving and pasting the rubber sheet on the corresponding position of the die after drying, compacting the surface of the rubber sheet, brushing the adhesive on a joint and the bonding area of the joint and the rubber sheet, putting the joint into the lower die after drying, compacting the joint, brushing the rubber sheet with the adhesive, and paving and pasting the rubber sheet on the surface of the joint after drying, and compacting the surface of the joint.
5. A method of manufacturing a rocket motor full composite shell according to claim 2, wherein the process of placing the anti-ablative braid is as follows: and coating adhesive on the surface of the ablation-resistant woven layer and the area bonded with the second rubber layer and the third rubber layer, paving an adhesive film on the surface after air drying, coating the adhesive on the surface of the adhesive film and the surface of the second rubber layer, and adhering and compacting after air drying.
6. A method for manufacturing a rocket engine full composite shell according to claim 1, wherein in step 5), the surface glue solution of the winding layer is scraped; and scraping the glue once every other time, controlling the surface of the winding layer to have no obvious glue residue, simultaneously weighing and detecting the scraped glue solution, and winding the waste gas if the viscosity exceeds a set range of 0.35-1.0 Pa.s.
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