CN113427752B - 一种连续纤维单向预浸带增材制造方法 - Google Patents

一种连续纤维单向预浸带增材制造方法 Download PDF

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CN113427752B
CN113427752B CN202110901116.2A CN202110901116A CN113427752B CN 113427752 B CN113427752 B CN 113427752B CN 202110901116 A CN202110901116 A CN 202110901116A CN 113427752 B CN113427752 B CN 113427752B
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吕明迪
关昊辰
杨朝坤
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Shandong Zhongheng Jingxin Carbon Fiber Science & Technology Development Co ltd
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    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract

本发明公开了一种连续纤维单向预浸带增材制造方法，包括对产品进行三维建模，并通过软件根据三维模型进行产品的应力仿真，得到产品的应力仿真图；3D打印机根据三维模型预设打印路径，根据打印路径，使用扁口打印头对连续纤维预浸扁带进行预应力逐层打印，转动扁口打印头根据应力仿真图在每层上定向铺设连续纤维预浸扁带，得到产品预制体；对产品预制体进行高压固化工艺得到产品胚体；对产品胚体进行机加工和涂装处理，得到最终产品。本发明为快速成型连续纤维复合材料和三维纤维预制体成型提供了可靠、快速、低成本的制造手段，为复合材料增材制造开辟的发展方向，将颠覆高性能热固性树脂的复合材料制造产业模式。

Description

一种连续纤维单向预浸带增材制造方法
技术领域
本发明涉及3D打印的技术领域，特别是涉及一种连续纤维单向预浸带增材制造方法。
背景技术
随着纤维复合材料的广泛应用越来越广泛以及3D打印技术的飞速发展，复合材料连续纤维的3D打印正在处于厚积薄发的新阶段，在新产品开发、模具制造及机械加工领域，已出现爆发式增长态势。
目前采用原位浸渍、丝束共挤出、拖丝挤出和原位合并等方法，解决了连续纤维增材制造的一部分问题，但也带来了一些新的问题，如纤维综合性能降低、更高的树脂质量要求等问题；同时圆形截面的连续纤维预浸带容易出现打印间隙，打印厚度不容易控制，成品易开裂等问题。
发明内容
本发明的目的是提供一种连续纤维单向预浸带增材制造方法，以解决上述现有技术存在的问题，使连续纤维预浸带打印厚度易控制，更容易制得孔隙率低、不易开裂的高质量产品。
为实现上述目的，本发明提供了如下方案：
本发明提供了一种连续纤维单向预浸带增材制造方法，包括如下步骤，
步骤一，对产品进行三维建模，并通过软件根据三维模型进行所述产品的应力仿真，得到所述产品的应力仿真图；
步骤二，3D打印机根据三维模型预设打印路径，根据所述打印路径，使用扁口打印头对连续纤维预浸扁带进行预应力逐层打印，转动所述扁口打印头根据所述应力仿真图在每层上定向铺设所述连续纤维预浸扁带，剪切多余材料，得到产品预制体；
步骤三，对所述产品预制体进行高压固化工艺得到产品胚体；
步骤四，对所述产品胚体进行机加工和涂装处理，得到最终产品。
优选的，所述步骤二中预应力逐层打印时施加的预应力为100-600N。
优选的，所述步骤二中预应力逐层打印至少包括与所述预设运动轨迹重合的平铺型、正倾斜角锯齿型和负倾斜角锯齿型三种打印轨迹，所述正倾斜角锯齿型和所述负倾斜角锯齿型的齿尖关于所述预设运动轨迹对称。
优选的，所述步骤二中预应力逐层打印中，每层为一种打印轨迹，三种所述打印轨迹交替使用，三种所述打印轨迹的顺序为六种排列组合的任意一种组合。
优选的，按照所述平铺型的打印轨迹最多连续打印三层，所述正倾斜角锯齿型和所述负倾斜角锯齿型的两层打印轨迹相邻且为一层锯齿构层，所述锯齿构层最多连续打印三层。
优选的，所述正倾斜角锯齿型和所述负倾斜角锯齿型与所述平铺型的运动轨迹之间的夹角为1°-90°。
优选的，所述扁口打印头上设施有加热器，所述加热器的温度控制在35℃-75℃。
优选的，所述连续纤维预浸扁带的横截面为矩形、腰型或者椭圆形，所述连续纤维预浸扁带的材质为碳纤维、玻璃纤维或者芳纶纤维。
优选的，所述高压固化工艺为热压罐或袋压工艺真空复合。
本发明相对于现有技术取得了以下技术效果：
本发明充分利用现有连续纤维预浸料的资源优势，进行无模具增材制造，使用连续纤维预浸扁带，使3D打印的每层厚度易控制，更容易制得孔隙率低、不易开裂的高质量产品，可使增材制造变得更加贴近工程化，实用性强，尤其是对于热固性树脂复合材料的低成本、快速加工生产具有重大意义。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明连续纤维单向预浸带增材制造方法的结构示意图一；
图2为本发明连续纤维单向预浸带增材制造方法的结构示意图二；
图3为本发明中预应力逐层打印的结构示意图；
其中：1-无尘箱，2-连续纤维预浸扁带，3-扁口打印头，4-平铺型，5-正倾斜角锯齿型，6-负倾斜角锯齿型，7-产品预制体，8-预设运动轨迹。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有付出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明的目的是提供一种连续纤维单向预浸带增材制造方法，以解决现有技术存在的问题，使。
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图和具体实施方式对本发明作进一步详细的说明。
如图1至图3所示：本实施例提供了一种连续纤维单向预浸带增材制造方法，包括如下步骤：
步骤一，对产品进行三维建模，并通过软件根据三维模型进行产品的应力仿真，得到产品的应力仿真图；
步骤二，3D打印机根据三维模型预设打印路径，根据打印路径，使用扁口打印头3对连续纤维预浸扁带2进行预应力逐层打印，转动扁口打印头3根据应力仿真图在每层上定向铺设连续纤维预浸扁带2，剪切多余材料，得到产品预制体7；扁口打印头3上设施有加热器，扁口打印头3能受机械手控制进行360°旋转，可任意改变打印角度，使打印出的连续纤维预浸扁带2按预设路径逐层打印；加热器的温度控制在35℃-75℃，优选加热温度为45℃，使所述纤维预浸扁带具有一定黏度，便于层间进行粘结。
其中，连续纤维预浸扁带2的横截面为矩形、腰型或者椭圆形，连续纤维预浸扁带2的材质为碳纤维、玻璃纤维或者芳纶纤维。预应力逐层打印时施加的预应力为100-600N，可使得纤维具有一定的张力，纤维路径更容易拉直，成型性更好，力学性能更优。
预应力逐层打印至少包括与预设运动轨迹8重合的平铺型4、正倾斜角锯齿型5和负倾斜角锯齿型6三种打印轨迹，正倾斜角锯齿型5和负倾斜角锯齿型6的齿尖关于预设运动轨迹8对称。预应力逐层打印中，每层为一种打印轨迹，三种打印轨迹交替使用，三种打印轨迹的顺序为六种排列组合的任意一种组合。按照平铺型4的打印轨迹最多连续打印三层，正倾斜角锯齿型5和负倾斜角锯齿型6的两层打印轨迹相邻且为一层锯齿构层(正倾斜角锯齿型5和负倾斜角锯齿型6的两层打印轨迹先后顺序均可)，锯齿构层最多连续打印三层。正倾斜角锯齿型5和负倾斜角锯齿型6与平铺型4的运动轨迹之间的夹角为1°-90°。本实施例中的夹角(正负倾斜角)为45°，经过锯齿型打印轨迹的叠加，有效防止层间开裂，增加了产品预制体7的抗压性能和抗振动性能，尤其是薄壁吸能件的产品性能。
本实施例的预应力逐层打印过程在透明的无尘箱1内进行，连续纤维预浸带卷装放置于无尘箱1外部轴架上，无尘箱1内设置有冷气管，冷气管与打印头固定连接，冷气管对准打印头，使得预浸带固化过程更迅速，提高工作效率。打印完成后，按照设计的纤维铺放长度，用剪裁装置对模具边缘多余的预浸料进行裁剪。
步骤三，对产品预制体7进行高压固化工艺得到产品胚体。其中，高压固化工艺为热压罐或袋压工艺真空复合，使产品胚体高温高压固化，得到孔隙率≤1.5％的高质量连续纤维增强复合材料零部件制品。
步骤四，对产品胚体进行机加工和涂装处理，得到最终产品。
本实施例为快速成型连续纤维复合材料提供了可靠的制造方法，为三维纤维预制体成型提供了快速、低成本的制造手段，为复合材料增材制造开辟的发展方向，将颠覆高性能热固性树脂的复合材料制造产业模式。
当打印12K碳纤维/环氧树脂预浸料单向带时，打印运动轨迹为交替隔层打印，即一层平铺型4，接着一层正倾斜角锯齿型5和负倾斜角锯齿型6的锯齿构层打印，循环下去。当打印6K碳纤维/环氧树脂预浸料单向带时，预浸料中的树脂采用光固化树脂，需要保存在暗室仓库，打印运动轨迹为上述的交替隔层打印。当打印12K碳纤维/环氧树脂预浸料单向带时，打印运动轨迹为每两层连续打印，即两层平铺型4，接着两层正倾斜角锯齿型5和负倾斜角锯齿型6的同样顺序的锯齿构层打印，循环下去。当打印玻璃纤维/环氧树脂预浸料单向带时，打印运动轨迹为上述的交替隔层打印。当打印3K碳纤维/聚酯树脂预浸料单向带时，打印运动轨迹为上述的交替隔层打印。当打印12K碳纤维/玻纤/环氧树脂预浸料单向带时，打印运动轨迹为混杂层打印，即一层连续碳纤维预浸料单向带平铺型4，接着一层连续玻纤预浸料单向带平铺型4，一层连续碳纤维预浸料单向带正(或负)倾斜角锯齿型5，接着一层连续玻纤预浸料单向带负(或正)倾斜角锯齿型6打印，循环下去。
本说明书中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处。综上所述，本说明书内容不应理解为对本发明的限制。

Claims (8)

1.一种连续纤维单向预浸带增材制造方法，其特征在于：包括如下步骤，
步骤一，对产品进行三维建模，并通过软件根据三维模型进行所述产品的应力仿真，得到所述产品的应力仿真图；
步骤二，3D打印机根据三维模型预设打印路径，根据所述打印路径，使用扁口打印头对连续纤维预浸扁带进行预应力逐层打印，转动所述扁口打印头根据所述应力仿真图在每层上定向铺设所述连续纤维预浸扁带，剪切多余材料，得到产品预制体；所述预应力逐层打印至少包括与所述预设运动轨迹重合的平铺型、正倾斜角锯齿型和负倾斜角锯齿型三种打印轨迹，所述正倾斜角锯齿型和所述负倾斜角锯齿型的齿尖关于所述预设运动轨迹对称；
步骤三，对所述产品预制体进行高压固化工艺得到产品胚体；
步骤四，对所述产品胚体进行机加工和涂装处理，得到最终产品。
2.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述步骤二中预应力逐层打印时施加的预应力为100-600N。
3.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述步骤二中预应力逐层打印中，每层为一种打印轨迹，三种所述打印轨迹交替使用，三种所述打印轨迹的顺序为六种排列组合的任意一种组合。
4.根据权利要求3所述的连续纤维单向预浸带增材制造方法，其特征在于：按照所述平铺型的打印轨迹最多连续打印三层，所述正倾斜角锯齿型和所述负倾斜角锯齿型的两层打印轨迹相邻且为一层锯齿构层，所述锯齿构层最多连续打印三层。
5.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述正倾斜角锯齿型和所述负倾斜角锯齿型与所述平铺型的运动轨迹之间的夹角为1°-90°。
6.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述扁口打印头上设施有加热器，所述加热器的温度控制在35℃-75℃。
7.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述连续纤维预浸扁带的横截面为矩形、腰型或者椭圆形，所述连续纤维预浸扁带的材质为碳纤维、玻璃纤维或者芳纶纤维。
8.根据权利要求1所述的连续纤维单向预浸带增材制造方法，其特征在于：所述高压固化工艺为热压罐或袋压工艺真空复合。
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