CN113681906B - Design method of ultrasonic welding lap joint of thermoplastic fiber reinforced composite material - Google Patents
Design method of ultrasonic welding lap joint of thermoplastic fiber reinforced composite material Download PDFInfo
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- CN113681906B CN113681906B CN202110814578.0A CN202110814578A CN113681906B CN 113681906 B CN113681906 B CN 113681906B CN 202110814578 A CN202110814578 A CN 202110814578A CN 113681906 B CN113681906 B CN 113681906B
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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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1228—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one monotone curved joint-segment
- B29C66/12281—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one monotone curved joint-segment the two joint-segments being monotone curved
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
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- 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
- B29L2007/00—Flat articles, e.g. films or sheets
- B29L2007/002—Panels; Plates; Sheets
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
The invention discloses a design method of an ultrasonic welding lap joint of a thermoplastic fiber reinforced composite material, belonging to the technical field of welding of the fiber reinforced thermoplastic composite material. The lap joint curved surface is further extended by a S-shaped seam curve generated by a plurality of nodes through cubic spline interpolation, the S-shaped seam curve has two extreme points, the problem of uneven distribution of joint welding points can be effectively solved through the design, the welding of a thermoplastic fiber reinforced composite medium plate can be realized, the S-shaped lap joint melting behavior occurs in multiple layers of the longitudinal direction of a welding piece, the welding penetration can be increased, and the stress concentration of a joint area can be effectively improved.
Description
Technical Field
The invention belongs to the technical field of welding of fiber reinforced thermoplastic composite materials, and mainly relates to a design method of an ultrasonic welding lap joint of a thermoplastic fiber reinforced composite material.
Background
Fiber reinforced thermoplastic composite materials are becoming a new generation of lightweight materials, and are receiving more and more attention due to their superior comprehensive mechanical properties (high specific strength, high specific modulus, good fatigue resistance, low thermal expansion coefficient, etc.), lower production cost (injection molding, extrusion or die pressing), and assembly cost (weldable), and recyclability. Effective joining technology is one of the key technologies for realizing large-scale industrial application of fiber reinforced thermoplastic composite materials.
Since the thermoplastic matrix of the fiber reinforced thermoplastic composite material has high viscosity, which limits the size of the member to be formed, efficient joining techniques are required to achieve the splicing of the fiber reinforced composite material plates. In the existing connection technology, the adhesive bonding needs surface treatment and extra baking, and has requirements on the operation environment; riveting can generate stress concentration, is easy to be electrochemically corroded, and can generate extra weight; welding is resistance welding, induction welding and ultrasonic welding, but ultrasonic welding is considered to be the most suitable method for welding thermoplastic materials due to its cleanliness, high efficiency and flexible operation.
In the process of ultrasonic welding of the fiber reinforced thermoplastic composite material, the traditional joint mostly adopts the forms of plane lapping, step lapping and the like, and energy generated by ultrasonic welding high-frequency vibration is longitudinally transmitted in a joint area, so that the melting behavior of the joint area in the traditional step lapping form is concentrated on a contact surface in the horizontal direction, the longitudinal contact part of the joint has incomplete melting, and the defects of stress concentration and the like are easy to occur under the action of load, so that the mechanical property and the stability of the step joint are influenced; secondly, welding spots at the joint are distributed unevenly, so that an ideal welding line cannot be formed, and the performance of the joint is also influenced.
The existing solution needs to inject an energy guiding rib on the plane of the joint, so that the problem of uneven distribution of welding spots is solved by accelerating heating, and the welding cost is increased. In addition, most of the conventional ultrasonic welding processes and methods aim at welding thin plates of fiber reinforced thermoplastic composite materials with the thickness of about 4mm, and related documents are few reports on the welding processes and joint design methods of thick plate members of thermoplastic composite materials.
Disclosure of Invention
Aiming at the problems that welding spots in a joint area are unevenly distributed and welding of medium-thickness plate members is difficult to realize in the existing ultrasonic welding process of composite materials, the invention provides the design method of the ultrasonic welding lap joint of the thermoplastic fiber reinforced composite material, which has the advantages of simple process, good welding effect and strong applicability, can effectively improve uneven distribution of the welding spots of the joint and can realize welding of the medium-thickness plate of the thermoplastic fiber reinforced composite material.
In order to solve the technical problems, the invention adopts the technical scheme that: the ultrasonic welding lap joint of the thermoplastic fiber reinforced composite material comprises a lap joint body, wherein a seam of the lap joint body is in a S-shaped curved surface.
The joint curve of the S-shaped curved surface has two extreme points.
A design method of an ultrasonic welding lap joint of a thermoplastic fiber reinforced composite material comprises the following steps:
determining the lap joint length: determining the length of a proper lap joint area according to the material properties and the thickness sizes of the to-be-welded parts of the two thermoplastic fiber reinforced composite materials;
selecting curve nodes: selecting a plurality of nodes required by the S-shaped seam curve by considering the thickness of a to-be-welded part of the thermoplastic fiber reinforced composite material, the energy transmission efficiency and the joint strength after welding;
calculating a joint curve: performing interpolation calculation on the plurality of nodes selected in the step (2) by adopting a cubic spline curve;
step (4), constructing a joint curved surface: constructing a joint curved surface model by utilizing the cubic spline curve extension obtained in the step (3);
step (5) forming a lap joint: and (3) butting the joint curved surfaces of the two pieces to be welded of the thermoplastic fiber reinforced composite material to finally form the S-shaped curved surface overlap joint.
Preferably, the two thermoplastic fiber reinforced composite material welds are both carbon fiber reinforced PEEK plates.
In step (1), the rated power of the welding equipment is also determined when determining the length of the lap joint region.
In the step (2), a rectangular coordinate system is established by taking the lower vertex of the outer end face of the joint area as an origin, the end node coordinate is determined by the length of the lap joint area, the welding head is placed above the center line of the lap joint area, and the horizontal coordinate of the internal node is determined by the edges and the central position of the left side and the right side of the welding head; the internal node ordinate is determined by the thickness of the overlap area.
In the step (3), the nodes are interpolated by using cubic spline to obtain a seam curve equation S (x).
Preferably, the thickness of the to-be-welded piece of the thermoplastic fiber reinforced composite material is 8-15 mm. When the thickness of the weldment is less than 8mm, the weldment can be excessively molten, deformed and collapsed, even punctured and the like; when the thickness of the weldment is larger than 15mm, the weldment is not firmly welded, and the welding strength cannot meet the requirement.
Preferably, the length of the lap joint area is 20-30 mm. The dispersion degree of welding energy has been decided to ultrasonic bonding's area size, and when overlap joint length was greater than 30mm, the energy can be too dispersed, can appear connecting the incomplete, inhomogeneous phenomenon of melting, can increase the processing degree of difficulty that connects the curve when overlap joint length is less than 20 mm.
Preferably, the diameter of the welding head is 14-20 mm. The size of the welding head is determined by the welding area, namely the lap length in the invention, and the diameter range of the welding head is 14-20 mm selected from the range of the lap length of 20-30 mm.
Compared with the prior art, the invention has the beneficial effects that: the S-shaped lap joint melting behavior of the invention occurs in a plurality of layers in the longitudinal direction of the weldment, the welding penetration can be increased, the good heat conduction effect of the carbon fiber can lead the thermoplastic matrix of the parent metal to be melted more quickly and uniformly, the carbon fiber in the layer can be tangled and interwoven during welding, and the joint strength can be effectively improved. Because the S-shaped lap joint contact area is larger, more friction heat is generated, the seam transition is smoother, and the stress concentration of the joint area can be effectively improved. In addition, the S-shaped lapping process is simple, welding points are uniformly distributed, the applicability is strong, the thickness of a component to be welded can be increased under the same energy input condition, and the weldability of the composite medium plate is improved under the same energy input condition.
Drawings
The advantages and realisation of the invention will be more apparent from the following detailed description, given by way of example, with reference to the accompanying drawings, which are given for the purpose of illustration only, and which are not to be construed in any way as limiting the invention, and in which:
FIG. 1 is a schematic view of the overlapping of the same thickness plates according to the present invention
FIG. 2 is a schematic view of the overlapping of different thickness plates according to the present invention
FIG. 3 is a cubic spline interpolation curve for the same sheet thickness according to the present invention
FIG. 4 is a cubic spline interpolation curve for different plate thicknesses
FIG. 5 is a schematic view of the lower plate of the present invention
FIG. 6 is a schematic view of the upper plate of the present invention
In the figure:
1. upper plate 2, lower plate 3, ultrasonic welding head
Detailed Description
The invention will be further described with reference to the following examples and figures:
the rated power of the multifunctional ultrasonic welding machine selected by the invention is 2.6KW, and the rated frequency is 20 KHz.
Example 1: as shown in figures 1, 3, 5 and 6,
in the ultrasonic welding overlap joint of the thermoplastic fiber reinforced composite material designed in the embodiment, the upper plate 1 and the lower plate 2 in the joint area are overlapped by adopting a multi-section curved surface to form an overlap joint body, and a seam of the overlap joint body is in a S-shaped curved surface.
The upper plate 1 and the lower plate 2 are made of carbon fiber reinforced PEEK plates with the size of 100mm multiplied by 30mm multiplied by 10mm, and an ultrasonic welding head 3 is applied to the right above the joint with certain pressure during welding, as shown in figure 1. The S-shaped curved surface is further extended by using S-shaped seam curve produced by utilizing cubic spline interpolation of several nodes, and said S-shaped seam curve has two extreme points.
The method for designing the ultrasonic welding lap joint of the thermoplastic fiber reinforced composite material comprises the following steps:
determining the length of a lap joint area: when the thicknesses of the upper plate 1 and the lower plate 2 are the same and 10mm, considering the power of the selected welding equipment and the processing difficulty of a joint curve, selecting the length of an overlapping area to be 25mm, and selecting the diameter of the ultrasonic welding head 3 to be 15mm according to the length of the overlapping area;
step (2), curve nodes are selected: firstly, establishing a rectangular coordinate system shown in fig. 3 by taking the lower vertex of the outer end face of the joint area in the upper plate 1 as an origin, and determining nodes A (0, 10) and E (25, 0) according to the length of the lap joint area; since the area of the weldment covered by the bottom of the ultrasonic horn 3 is the main area where the melting action occurs during the welding process, the ultrasonic horn 3 is placed above the center line of the lap joint area, as shown in fig. 3, the abscissa of the node B, D is determined by the left and right edges of the ultrasonic horn 3, and the abscissa of the node C is determined by the center of the ultrasonic horn 3. In order to ensure that energy transmission is stable, welding points are uniformly distributed and the thicknesses of upper and lower weldments in a lap joint area are similar, the ordinate of B, C, D three nodes is 5, so that nodes B (5, 5) and C (12.5, 5) and D (20, 5) are provided;
calculating a joint curve: obtaining a seam curve equation S (x) by utilizing cubic spline interpolation on the five nodes selected in the step (2);
step (4), constructing a joint curved surface: performing horizontal extension by using the joint curve equation S (x) calculated in the step (3) and constructing a three-dimensional model of a joint curved surface;
step (5) forming a lap joint: and (3) butting the joint curved surfaces of the upper plate 1 and the lower plate 2 to finally form an S-shaped curved surface overlap joint.
The key to generating the "S-shaped curved surface joint" of the present embodiment is designing and calculating the corresponding joint curve (see FIG. 3), and thus the present invention performs detailed calculations to arrive at equation S (x).
Given y ═ f (x) node (x) i ,f(x i ) (i-0, 1, … n) and S (x) i )＝f(x i ) Let S (x) be S j (x),x∈[x j ,x j+1 ]In which S is j (x) Is a cubic interpolation spline function, so S j "(x) is in [ x ] j ,x j+1 ]The above is a linear function, and is known from lagrange interpolation:
h j ＝x j+1 -x j ,S”(x j )＝M j ,(j＝0,1,…n)
integrating the above equation yields:
and then obtaining by integration:
from the condition S (x) j )＝y j ,S(x j+1 )＝y j+1 Determining an integration constant c 1 ,c 2 。
C is to be 1 ,c 2 Substituting the formula (1) to obtain a cubic spline interpolation function to obtain an expression:
in the formula (2), x is ∈ [ x ] j ,x j+1 ]
To determine M 0 ,…,M n The derivative continuous condition S' (x) is used j +0)＝S'(x j -0), deriving s (x) to obtain:
the same can be obtained:
will S' (x) j +0)、S'(x j -0) into equations (3) (4) respectively and making both equal can be obtained:
order to
Therefore, when equation (6) is substituted into equation (5), the following can be obtained:
μ j M j-1 +2M j +λ j M j+1 ＝d j ,j＝1,…,n-1
namely:
for example 1 above, take 5 nodes:
x 0 ＝0,x 1 ＝5,x 2 ＝12.5,x 3 ＝20,x 4 ＝25
y＝f(x),f(x 0 )＝10,f(x 1 )＝5,f(x 2 )＝5,f(x 3 )＝5,f(x 4 )＝0
given the boundary conditions:
S”(x 0 )＝M 0 ＝f 0 ”,S”(x n )＝M n ＝f n ”
equation (7) can be written as:
for this example only f needs to be satisfied 0 "> 0 (the curve of the initial segment is a concave function), f n "< 0 (the curve at the end segment is a convex function), and particularly, since the five nodes taken in the present example are centrosymmetric with respect to the point C, when f 0 ”＝-f n "the curve obtained will also be symmetrical about the center of the node C, in this case M 0 ＝f 0 ”＝0.3,M n ＝f n ”＝-0.4。
According to equation (6) there is:
λ 1 ＝0.6,λ 2 ＝0.5,λ 3 ＝0.4
μ 1 ＝0.4,μ 2 ＝0.5,μ 3 ＝0.6
d 1 ＝0.48,d 2 ＝0,d 3 ＝-0.48
the data described above can be substituted into the following formula (8):
obtaining by solution: m 1 ＝0.1818,M 2 ＝-0.0059,M 3 ＝-0.1582
The expression of the cubic spline interpolation curve can be obtained according to the formula (2):
example 2: as shown in figures 2 and 4 to 6,
in the ultrasonic welding overlap joint of the thermoplastic fiber reinforced composite material designed in the embodiment, the upper plate 1 and the lower plate 2 in the joint area are overlapped by adopting a multi-section curved surface to form an overlap joint body, and a seam of the overlap joint body is in a S-shaped curved surface.
The upper plate 1 and the lower plate 2 are both made of carbon fiber reinforced PEEK plates, wherein the upper plate 1 has a dimension specification of 100mm multiplied by 30mm multiplied by 12mm, and the lower plate 2 has a dimension specification of 100mm multiplied by 30mm multiplied by 10 mm. During welding, the ultrasonic horn 3 is applied with a certain pressure directly above the joint, as shown in fig. 2. The S-shaped curved surface is further extended by using S-shaped seam curve produced by utilizing cubic spline interpolation of several nodes, and said S-shaped seam curve has two extreme points.
The method for designing the ultrasonic welding lap joint of the thermoplastic fiber reinforced composite material comprises the following steps:
determining the length of a lap joint area: for an upper plate 1 with the thickness of 12mm and a lower plate 2 with the thickness of 10mm, considering the power of the selected welding equipment and the processing difficulty of a joint curve, selecting the length of an overlapping area to be 25mm, and then selecting the diameter of an ultrasonic welding head 3 to be 15mm according to the length of the overlapping area;
selecting curve nodes: firstly, establishing a rectangular coordinate system shown in fig. 4 by taking the vertex of the lower part of the outer end face of a joint area in the upper plate 1 as an origin, and determining nodes A (0, 10) and D (25, 0) according to the length of a lap joint area; because the area of the weldment covered by the ultrasonic welding head 3 is the main area where the melting behavior occurs in the welding process, the ultrasonic welding head 3 is placed above the center line of the lap-joint area, as shown in fig. 4, the abscissa of the node B, C is determined by the edges of the left side and the right side of the ultrasonic welding head 3, and then the ordinate of the B, C two nodes is taken as 6, so that the thicknesses of the upper weldment and the lower weldment in the lap-joint area are close to ensure that the energy transmission is stable and the welding points are distributed uniformly in the welding process, and therefore, the nodes B (5, 6) and the nodes C (20, 6) are provided.
Calculating a joint curve: obtaining a seam curve equation S (x) by utilizing cubic spline interpolation on the four nodes selected in the step (2);
step (4), constructing a joint curved surface: performing horizontal extension by using the joint curve equation S (x) calculated in the step (3) and constructing a three-dimensional model of a joint curved surface;
step (5) forming a lap joint: and (3) butting the joint curved surfaces of the upper plate 1 and the lower plate 2 to finally form an S-shaped curved surface overlap joint.
The key to generating the "-" shaped curved surface joint of this embodiment is to design a corresponding joint curve (see FIG. 4).
The 4 nodes taken for the above embodiment:
x 0 ＝0,x 1 ＝5,x 2 ＝20,x 3 ＝25
y＝f(x),f(x 0 )＝10,f(x 1 )＝6,f(x 2 )＝6,f(x 3 )＝0
given the boundary conditions:
S”(x 0 )＝M 0 ＝f 0 ”,S”(x n )＝M n ＝f n ”
for this example only f needs to be satisfied 0 "> 0 (the curve of the initial segment is a concave function), f n "< 0 (the curve at the tail section is a convex function), and M is taken in the example 0 ＝f 0 ”＝0.4,M n ＝f n ”＝-0.5。
According to equation (6) there is:
λ 1 ＝0.75,λ 2 ＝0.25
μ 1 ＝0.25,μ 2 ＝0.75
d 1 ＝0.24,d 2 ＝-0.36
the data can be substituted into the formula (8):
obtaining by solution: m 1 ＝0.1327,M 2 ＝-0.1673
Obtaining a cubic spline interpolation curve expression according to the formula (2):
the embodiments of the present invention have been described in detail, but the description is only for the preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made within the scope of the present invention should be covered by this patent.
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| JP2012176514A (en) * | 2011-02-25 | 2012-09-13 | Fuji Heavy Ind Ltd | Structure and method for joining fiber reinforced resin and metal |
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| CN112026185A (en) * | 2020-07-29 | 2020-12-04 | 天津大学 | Ultrasonic thermoplastic material welding method, energy-conducting component and application thereof |
| CN112277337B (en) * | 2020-09-27 | 2022-09-09 | 湖北三江航天江北机械工程有限公司 | Laser welding forming method for sectional type composite material shell of solid rocket engine |
| CN112776348B (en) * | 2021-02-01 | 2022-07-19 | 北京工业大学 | Fiber reinforced thermoplastic composite material and metal laser pressure welding method |
| CN112936876A (en) * | 2021-02-02 | 2021-06-11 | 西安交通大学 | Ultrasonic welding method for interface inclusion reinforced thermoplastic composite material |
| CN113043604B (en) * | 2021-02-04 | 2022-02-08 | 东华大学 | Induction welding method for thermoplastic composite material with high welding strength and implanted layer |
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| JP2012176514A (en) * | 2011-02-25 | 2012-09-13 | Fuji Heavy Ind Ltd | Structure and method for joining fiber reinforced resin and metal |
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Effective date of registration: 20221129 Address after: 1-1-107, No. 2, Haitai Chuangxin 6th Road, Huayuan Industrial Zone, Binhai New Area, Tianjin 300450 Patentee after: Tianjin Zhongjiang Automation Technology Co.,Ltd. Address before: No. 399, Binshui West Road, Xiqing District, Tianjin Patentee before: TIANJIN POLYTECHNIC University |
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Application publication date: 20211123 Assignee: TIANJIN TIANYUANHAI TECHNOLOGY DEVELOPMENT Co.,Ltd. Assignor: Tianjin Zhongjiang Automation Technology Co.,Ltd. Contract record no.: X2023980044154 Denomination of invention: Design Method for Ultrasonic Welding Lap Joint of Thermoplastic Fiber Reinforced Composite Materials Granted publication date: 20220923 License type: Common License Record date: 20231023 |
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Application publication date: 20211123 Assignee: TIANJIN SANTE ELECTRONICS CO.,LTD. Assignor: Tianjin Zhongjiang Automation Technology Co.,Ltd. Contract record no.: X2023980044704 Denomination of invention: Design Method for Ultrasonic Welding Lap Joint of Thermoplastic Fiber Reinforced Composite Materials Granted publication date: 20220923 License type: Common License Record date: 20231026 |
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