CN113844078A - Preparation method of ultra-light multi-feature skin-free framework type composite shell - Google Patents
Preparation method of ultra-light multi-feature skin-free framework type composite shell Download PDFInfo
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Abstract
The invention relates to a preparation method of an ultra-light multi-feature skin-free framework type composite shell, which realizes the accurate numerical control automatic winding of equidistant spiral ribs and annular rib hot-melt prepreg filaments of a non-geodesic wire and the alternate implementation of framework rib strips and multi-feature structure laying by arranging a freely movable seal head guiding and positioning device and an automatic winding linear track planning. Aiming at a multi-feature skin-free framework type structure, the number of winding cycles of framework rib hot-melt prepreg filaments, a layer laying structure of a balanced cross-coupling rib winding-end frame-opening reinforcement area, rib scattering and the like are accurately calculated through a balanced cross-coupling layer laying structure design, so that the uniform and effective connection of side wall flanging, end frames and framework ribs is realized, and the integral rigidity and stability of a product are ensured. By optimizing the design of the framework rib R-angle die, the pre-compaction control technology and the reasonable curing process, the defects of poor rib size precision, rib defects and product quality defects caused by the problem of curing, pressurizing and interfering of multi-feature structures due to rib overflow edges of the skin-free framework are overcome, the high-quality and high-size-precision integrated molding of the ultra-light multi-feature skin-free framework composite material shell is realized, the weight is reduced by more than 30% compared with that of the traditional skin structure, and the requirement of the aerospace model on light weight is met.
Description
Technical Field
The invention relates to a preparation method of an ultra-light multi-feature skin-free framework type composite shell, belonging to the field of composite materials and processes.
Background
The advanced composite material framework structure has the characteristics of good geometric topological optimization, excellent structural bearing performance, high specific strength, high specific stiffness and the like, and is increasingly widely applied to the field of aerospace.
The composite material skeleton structure without the skin has the advantages of high self-stability, strong buckling resistance, strong optimization, low initial defect sensitivity, uniform stress distribution, effective load distribution and the like while inheriting the advantages of the composite material skeleton structure, and is unique: both calculation and tests show that the bearing efficiency of the framework type ribs in the composite material framework type structure is far higher than that of a skin; the composite material with the skin-free framework structure is adopted, so that ultra-light structure can be realized; the weak bonding interface between the frame rib and the skin in the skin-frame structure is naturally overcome, and the bearing capacity of the structure is improved. At present, Russian and Indian advanced upper-level bearing cabins are successfully applied to skin-free skeleton structures. Because of no skin, the molding of the crossed joints of the framework ribs, the connection between the framework ribs and the end frame are more difficult, the problems of poor rib size precision and rib defects caused by serious rib edge overflow are prominent, and the skin-free composite material framework structure which is independently developed and produced at present is not applied to engineering practice at home.
In order to maximize the carrying capacity of a certain in-process solid carrier rocket, the advanced upper-level satellite bracket adopts an innovative ultra-light multi-feature skin-free framework type composite material design, and a preparation method of the multi-feature skin-free framework type structure has not been reported at home and abroad. How to solve the problem of high-efficiency, high-quality and high-dimensional precision integrated molding of an ultra-light multi-feature skin-free framework type composite material satellite support, and meeting the weight reduction requirement of a model structure is a key problem to be solved urgently.
Disclosure of Invention
The invention aims to provide a preparation method of an ultra-light multi-feature skin-free framework type composite material shell, which realizes the high-efficiency, high-quality and high-dimensional precision integrated molding of an ultra-light multi-feature skin-free framework type composite material satellite support and meets the weight reduction requirement of a model structure.
The above purpose of the invention is mainly realized by the following technical scheme:
a preparation method of an ultra-light multi-feature skin-free skeleton type composite shell is characterized by comprising the following steps:
(1) and sequentially installing a lower end socket guide positioning device, a main body forming die and an upper end socket guide positioning device on the main shaft, fixing the die on a numerical control winding machine, and moving the positioning device to be separated from the main body forming die by at least 150 mm.
(2) And carrying out automatic winding linear track planning according to the three-dimensional model of the product.
(3) And estimating the number of the prepreg filaments used by the framework ribs according to the three-dimensional model of the product by adopting a hot-melt prepreg method, and preparing the hot-melt prepreg filaments by using prepreg filament slitting equipment.
(4) Accurately calculating the size of the material for paving according to the three-dimensional model of the product by adopting a hot melting method for prepreg preparation, and accurately blanking by utilizing automatic blanking equipment;
(5) sequentially developing layers (1) at the upper end, the lower end and the opening reinforcement area, wherein the layers at the upper end and the lower end are inwards turned to the end frame area;
(6) moving the positioning device to be connected with a main body forming die, calling an automatic winding program, winding the spiral ribs and the annular ribs (1), cutting off the prepreg filaments at the joint of the main body forming die and the end socket after the winding is finished, and scattering the ribs at least into the flanges at the upper end and the lower end and the laying layer of the opening reinforcing area;
(7) alternately completing the ply laying and rib winding for n cycles to the rest 2-6 layers of ply laying and rib winding according to the methods of the steps (5) and (6), wherein n is a positive integer;
(8) according to the methods in the steps (6) and (5), winding and laying of the residual ribs are completed in sequence;
(9) and dismantling the two-end positioning device and the main shaft, assembling the mold, coating a vacuum bag, vacuumizing and curing.
(10) And after the curing is finished, demolding the product, locally polishing, removing edge burrs, and finishing the preparation of the ultra-light multi-feature skin-free framework type composite material shell.
In the above preparation method, the multi-feature shell structure comprises framework ribs, upper and lower side walls, an inward-turning end frame, a large opening, and an opening reinforcing region, and the side walls or the end frame can be of a variable-thickness structure.
In the preparation method, the end socket guiding and positioning device in the step (1) can freely move on the main shaft, and the type of the end socket can be an ellipse or a disc.
In the preparation method, the fillet of the side surface of the rib groove of the main body forming die is less than or equal to R0.5.
In the preparation method, X layers are completed by each cyclic layering, X is more than or equal to 5 and less than or equal to 10 and is a positive integer, Y bars are wound by each cyclic rib,
and Y is a positive integer, a is the prepreg filament width, and L is the tendon groove width.
In the preparation method, when the side wall or the end frame of the shell is of a variable-thickness structure, the layering in the steps (5) and (7) is carried out at a certain staggering speed.
In the preparation method, when the requirements on the dimensional accuracy of the upper end frame and the lower end frame are higher, after all layers are laid, the machining-added removing amount of the layers are added at the upper end frame and the lower end frame, and after a product is formed, the upper end frame and the lower end frame are processed to meet the requirements.
In the above production method, n cycles in the step (7),
where H1 is the total ply thickness, b is the single ply prepreg thickness, and X is the number of plies completed per cycle of ply layup.
In the preparation method, when the layering and rib winding are alternately finished in the step (7), the glue absorption and compaction are carried out after the thickness of 3 mm-6 mm and the step (7) are finished, the glue absorption temperature is 70-90 ℃, the heat preservation time is 30-90 min, and the pressure is 0.3 MPa-0.7 MPa.
In the above preparation method, the curing of step (9) comprises: under the pressure of 0.5MPa to 1.0MPa, the temperature is raised to 100 ℃ to 250 ℃ at the temperature raising rate of 5 ℃/h to 40 ℃/h, the heat preservation time is 2h to 8h, then the temperature is lowered to 40 ℃ to 70 ℃, and the temperature lowering rate is less than 30 ℃/h.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention adopts a forming die to prepare the ultra-light multi-feature skin-free framework type composite material shell, and realizes the accurate numerical control automatic winding of equidistant spiral ribs and annular rib hot-melt prepreg yarns of non-geodesic wires and the alternate implementation of the layering of framework ribs and multi-feature structures by arranging a freely movable seal head guiding and positioning device and planning the automatic winding linear track;
(2) according to the invention, a balanced cross-coupling layering structure is designed according to the relationship between the winding amount of the ribs and the layering amount of the multi-feature structure, the number of winding cycles of the framework ribs by using hot-melt prepreg, the layering structure of the balanced cross-coupling ribs in winding-end frame-opening reinforcement area, rib scattering and the like are accurately calculated, the uniform and effective connection of side wall flanging, end frames and the framework ribs is realized, and the integral rigidity and stability of the product are ensured;
(3) by optimizing the R-angle die design of the framework rib, the pre-compaction control technology and the reasonable curing process, the invention solves the problems of poor rib size precision, rib defect and product quality defect caused by multi-characteristic structure curing pressurization interference problem caused by rib overflow edge of the skin-free framework, and realizes the high-quality and high-size precision integrated molding of the ultra-light multi-characteristic skin-free framework composite material shell;
(4) compared with the traditional skin structural member, the multi-characteristic skin-free framework type composite material shell reduces the weight by more than 30 percent and meets the requirement of lightweight aerospace models.
Drawings
FIG. 1 is a schematic structural diagram of an ultra-lightweight multi-feature skin-less skeletal composite shell;
FIG. 2 is a flow chart of a process for preparing an ultra-light multi-feature skin-free skeleton composite shell.
FIG. 3 is a schematic view of a rib groove side fillet of the main body forming die.
Detailed Description
The embodiment of the invention provides a preparation method of an ultra-light multi-feature skin-free framework type composite shell, the shell comprises framework ribs, upper and lower side walls, upper and lower inward-turning end frames, a large opening and an opening reinforcing area as shown in figure 1, the side walls or the end frames can be of a variable-thickness structure, and the preparation method comprises the following steps:
(1) and sequentially installing a lower end socket guide positioning device, a main body forming die and an upper end socket guide positioning device on the main shaft, fixing the main shaft on a numerical control winding machine, and moving the positioning device to be separated from the main body forming die by at least 150 mm.
(2) And carrying out automatic winding linear track planning according to the product three-dimensional model, wherein the step is executed by adopting the existing method, and the geometric dimensions of the product and the auxiliary end socket are input in winding programming software according to the product three-dimensional model to carry out winding modeling.
(3) And estimating the number of the prepreg filaments used by the framework ribs according to the three-dimensional model of the product by adopting a hot-melt prepreg method, and preparing the hot-melt prepreg filaments by using prepreg filament slitting equipment.
(4) Accurately calculating the size of the material for paving according to the three-dimensional model of the product by adopting a hot melting method for prepreg preparation, and accurately blanking by utilizing automatic blanking equipment; the molded surface of the product is spread according to the three-dimensional model, the number of the layering material blocks of each layer is designed, and then the size of the material blocks is calculated.
(5) Sequentially developing layers (1) at the upper end, the lower end and the opening reinforcement area, wherein the layers at the upper end and the lower end are inwards turned to the end frame area;
(6) moving the positioning device to be connected with a main body forming die, calling an automatic winding program, winding the spiral ribs and the annular ribs (1), cutting off the prepreg filaments at the joint of the main body forming die and the end socket after the winding is finished, and scattering the ribs at least into the flanges at the upper end and the lower end and the laying layer of the opening reinforcing area;
(7) alternately completing the ply laying and rib winding for n cycles to the rest 2-6 layers of ply laying and rib winding according to the methods of the steps (5) and (6), wherein n is a positive integer;
(8) according to the methods in the steps (6) and (5), winding and laying of the residual ribs are completed in sequence;
(9) and dismantling the two-end positioning device and the main shaft, assembling the mold, coating a vacuum bag, vacuumizing and curing.
(10) And after the curing is finished, demolding the product, locally polishing, removing edge burrs, and finishing the preparation of the ultra-light multi-feature skin-free framework type composite material shell.
In the preparation method, the end socket guiding and positioning device in the step (1) can freely move on the main shaft, and the type of the end socket can be an ellipse or a disc.
In the preparation method, the fillet of the side surface of the rib groove of the main body forming die is not more than R0.5, which is shown in figure 3.
In the preparation method, X layers are completed by each cyclic layering, X is more than or equal to 5 and less than or equal to 10 and is a positive integer, Y bars are wound by each cyclic rib,
and Y is a positive integer, a is the prepreg filament width, and L is the tendon groove width.
In the preparation method, when the side wall or the end frame of the shell is of a variable-thickness structure, the layering in the steps (5) and (7) is carried out at a certain staggering speed.
In the preparation method, when the requirements on the dimensional accuracy of the upper end frame and the lower end frame are higher, after all layers are laid, the machining-removed amount of the layers are added at the upper end frame and the lower end frame, and after a product is formed, the upper end frame and the lower end frame are processed to meet the requirements that the end surface planeness is less than or equal to 0.1 mm.
In the above production method, n cycles in the step (7),
where H1 is the total ply thickness, b is the single ply prepreg thickness, and X is the number of plies completed per cycle of ply layup.
In the preparation method, when the layering and rib winding are alternately finished in the step (7), the glue absorption and compaction are carried out after the thickness of 3 mm-6 mm and the step (7) are finished, the glue absorption temperature is 70-90 ℃, the heat preservation time is 30-90 min, and the pressure is 0.3 MPa-0.7 MPa.
In the above preparation method, the step (9) of evacuating and curing includes: under the pressure of 0.5MPa to 1.0MPa, the temperature is raised to 100 ℃ to 250 ℃ at the temperature raising rate of 5 ℃/h to 40 ℃/h, the heat preservation time is 2h to 8h, then the temperature is lowered to 40 ℃ to 70 ℃, and the temperature lowering rate is less than 30 ℃/h.
The pre-compaction process parameters and the curing process parameters are optimally designed through a great number of experiments throughout the year, and the quality and the dimensional accuracy of the product are effectively ensured by adopting a reasonable autoclave pre-compaction and curing process; the defect percentage of the product is less than 1 percent, the requirement of 5 percent of design technical index is met, the weight is reduced by more than 30 percent compared with the traditional skin structural member, and the requirement of lightweight aerospace model is met.
Example 1
Product overview: the rib size 6mm 9mm, end frame, lateral wall, opening reinforcement district thickness are 9 mm. The preparation is carried out by adopting a hot-melt prepreg with the single-layer thickness of 0.15 mm.
The implementation steps are as follows:
(1) a lower end socket guiding and positioning device, a main body forming die (a core die and a split male die block) and an upper end socket guiding and positioning device are sequentially arranged on the main shaft, the die is fixed on a numerical control winding machine, and the positioning device is moved to be separated from the main body forming die by at least 150 mm.
(2) And carrying out automatic winding linear track planning according to the three-dimensional model of the product.
(3) The hot-melt prepreg is adopted, the hot-melt prepreg filaments with the width of 6mm are selected according to the three-dimensional model of the product, the number of the prepreg filaments used by the framework ribs is calculated to be 60, and the required hot-melt prepreg filaments are prepared by adopting prepreg filament slitting equipment.
(4) Accurately calculating the size of the material for paving according to the three-dimensional model of the product by adopting a hot melting method for prepreg preparation, and accurately blanking by utilizing automatic blanking equipment;
(5) sequentially spreading layers (1) in an upper end, a lower end and an opening reinforcement area, wherein the number of the layer layers X is 8, and the layer materials at the upper end and the lower end are inwards turned to an end frame area;
(6) moving the positioning device to be connected with a main body forming die, calling an automatic winding program, winding (1) spiral ribs and annular ribs, wherein the number of layers is Y equal to 8, cutting the prepreg filaments at the joint of the main body forming die and the end socket after finishing, and scattering the ribs at least into the layers of the flanges at the upper end and the lower end and the reinforcing area of the opening;
(7) alternately completing laying and rib winding for 7 cycles to the rest 4 layers according to the methods of the steps (5) and (6); after 3 cycles (thickness 3.6mm) and 7 cycles, performing glue absorption and compaction, wherein the glue absorption temperature is 90 ℃, the heat preservation time is 30min, and the pressure is 0.3 MPa.
(8) According to the methods in the steps (6) and (5), winding and laying of the residual ribs are completed in sequence;
(9) and dismantling the two-end positioning device and the main shaft, assembling the mold, coating a vacuum bag, vacuumizing and curing. Under the pressure of 0.6MPa, the temperature is raised to 160 ℃ at the temperature raising rate of 30 +/-5 ℃/h, the heat preservation time is 6h, then the temperature is lowered to 50 ℃, and the temperature lowering rate is less than 30 ℃/h.
The assembling die is formed by mounting an upper pressing ring, a lower pressing ring and an outer female die on the basis of a main body forming die.
(10) And after the curing is finished, demolding the product, locally polishing, removing edge burrs, and finishing the preparation of the ultra-light multi-feature skin-free framework type composite material shell.
Example 2
Product overview: the rib size 9mm 12mm, upper end frame, lateral wall, opening reinforcement district thickness are 12mm, and lower extreme frame thickness is from 12mm gradual change to 6 mm. The preparation is carried out by adopting a hot-melt prepreg with the single-layer thickness of 0.15 mm.
The implementation steps are as follows:
(1) and a lower end socket guide positioning device, a main body forming die and an upper end socket guide positioning device are sequentially arranged on the main shaft, the die is fixed on a numerical control winding machine, and the positioning device is moved to be separated from the main body forming die by at least 150 mm.
(2) And carrying out automatic winding linear track planning according to the three-dimensional model of the product.
(3) The hot-melt method is adopted for prepreg, hot-melt prepreg filaments with the width of 6mm are selected according to a three-dimensional model of a product, the number of the prepreg filaments used by the framework ribs is calculated to be 120, and the required hot-melt method prepreg filaments are prepared by adopting prepreg filament slitting equipment.
(4) Accurately calculating the size of the material for paving according to the three-dimensional model of the product by adopting a hot melting method for prepreg preparation, and accurately blanking by utilizing automatic blanking equipment;
(5) sequentially spreading layers (1) in an upper end, a lower end and an opening reinforcement area, wherein the number of the layer layers is 6, and the layer materials at the upper end and the lower end are inwards turned to an end frame area;
(6) moving the positioning device to be connected with a main body forming die, calling an automatic winding program, winding (1) spiral ribs and annular ribs, wherein the number of layers is Y equal to 9, cutting the prepreg filaments at the joint of the main body forming die and the end socket after finishing, and scattering the ribs at least into the layers of the flanges at the upper end and the lower end and the reinforcing area of the opening;
(7) and (5) alternately finishing laying, rib winding for 13 cycles to the rest 2 layers of laying and 3 rib winding according to the methods in the steps (5) and (6), wherein the lower end frame adopts a certain staggered layer speed to carry out laying, and the size requirement of gradually changing from 12mm to 6mm is met. After the 5 th cycle (thickness 5.4mm), the 10 th cycle (thickness 10.8mm) and the 13 th cycle are completed, glue absorption and compaction are carried out, the glue absorption temperature is 80 ℃, the heat preservation time is 60min, and the pressure is 0.4 MPa.
(8) According to the methods in the steps (6) and (5), winding and laying of the residual ribs are completed in sequence;
(9) and dismantling the two-end positioning device and the main shaft, assembling the mold, coating a vacuum bag, vacuumizing and curing. Under the pressure of 0.8MPa, the temperature is raised to 230 ℃ at the temperature raising rate of 25 +/-5 ℃/h, the heat preservation time is 6h, then the temperature is lowered to 60 ℃, and the temperature lowering rate is less than 30 ℃/h.
(10) And after the curing is finished, demolding the product, locally polishing, removing edge burrs, and finishing the preparation of the ultra-light multi-feature skin-free framework type composite material shell.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention, and those skilled in the art can make variations and modifications of the present invention without departing from the spirit and scope of the present invention by using the methods and technical contents disclosed above.
Claims (10)
1. A preparation method of an ultra-light multi-feature skin-free framework type composite shell is characterized in that a skin-free framework type composite shell structure comprises framework ribs, an upper side wall, a lower side wall, an upper inward-turning end frame, a lower inward-turning end frame, an opening and an opening reinforcing area, and the method comprises the following steps:
(1) the main shaft is sequentially provided with a lower end socket guide positioning device, a main body forming die and an upper end socket guide positioning device, wherein the main body forming die and the main shaft are fixed in relative position, and the upper end socket guide positioning device and the lower end socket guide positioning device can slide relative to the main shaft; fixing the main shaft on a numerical control winding machine, and moving the upper end socket guiding and positioning device and the lower end socket guiding and positioning device to be separated from the main body forming die by at least 150 mm;
(2) carrying out automatic winding linear track planning according to the three-dimensional model of the product;
(3) sequentially spreading layers on the upper end, the lower end and the opening reinforcement area by adopting a hot melting method to prepreg, wherein the upper end and the lower end of the spreading layer are inwards turned to the end frame area;
(4) moving the upper end socket guiding and positioning device and the lower end socket guiding and positioning device to be connected with the main body forming die, winding the spiral ribs and the annular ribs by using the hot-melt prepreg filaments according to the automatic winding linear track planned in the step (2), cutting the prepreg filaments at the joint of the main body forming die and the end sockets after the winding is finished, and separating the upper end socket guiding and positioning device and the lower end socket guiding and positioning device; the ribs are extended to the inner layer of the turnups at the upper end and the lower end and the openings of the reinforcing areas by at least 20mm and are uniformly dispersed;
(5) alternately finishing the laying, rib winding to the rest 2-6 layers of laying and rib winding according to the methods in the steps (3) and (4);
(6) according to the methods in the steps (4) and (3), winding and laying of the rest ribs are completed in sequence according to the sequence of winding the ribs firstly and then laying;
(7) dismantling the upper end socket guiding and positioning device and the lower end socket guiding and positioning device and the main shaft, assembling a mold, vacuumizing and curing;
(8) and after the curing is finished, demolding the product, locally polishing, removing edge burrs, and finishing the preparation of the ultra-light multi-feature skin-free framework type composite material shell.
2. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: the side wall or the end frame of the shell structure of the composite material without the skin skeleton is of a structure with equal thickness or variable thickness.
3. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 2, wherein the method comprises the following steps: and (5) when the side wall or the end frame of the shell is of a variable-thickness structure, performing staggered layering by adopting a preset staggered layering speed in the layering in the steps (3) and (5).
4. According to claim 3The preparation method of the ultra-light multi-feature skin-free framework type composite shell is characterized by comprising the following steps of: the staggered-layer speed V is L1H/. DELTA.H, wherein L1In order to increase the length of the thickness structure, H is the thickness of the single-layer hot-melt prepreg, and Δ H is the thickness difference.
5. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: the fillet of the side surface of the rib groove of the main body forming die is less than or equal to R0.5.
6. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: in the step (3), X layers are completed in each circulation layering, X is more than or equal to 5 and less than or equal to 10 and is a positive integer, Y circulation ribs are wound,
and Y is a positive integer, wherein a is the prepreg filament width and L is the tendon groove width.
7. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: and (4) after all layers are laid in the step (6), adding machining removal quantity layers at the upper end frame and the lower end frame, and processing the upper end frame and the lower end frame after the product is formed until the requirements are met so as to improve the dimensional accuracy requirements of the upper end frame and the lower end frame.
8. The method for preparing the ultra-light multi-feature skin-free skeleton composite shell according to claim 1 or 6, wherein the method comprises the following steps: in the step (5), n circulation finishes laying and rib winding alternately,
where H1 is the total ply thickness, b is the single ply prepreg thickness, and X is the number of plies completed per cycle of ply layup.
9. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: and (3) paving and rib winding with the thickness of 3-6 mm are completed in the step (5), and glue absorption and compaction are carried out after the step (5) is completed, wherein the glue absorption temperature is 70-90 ℃, the heat preservation time is 30-90 min, and the pressure is 0.3-0.7 MPa.
10. The method for preparing the ultra-light multi-feature skin-free framework type composite shell according to claim 1, wherein the method comprises the following steps: the curing of step (7), comprising: under the pressure of 0.5MPa to 1.0MPa, the temperature is raised to 100 ℃ to 250 ℃ at the temperature raising rate of 5 ℃/h to 40 ℃/h, the heat preservation time is 2h to 8h, then the temperature is lowered to 40 ℃ to 70 ℃, and the temperature lowering rate is less than 30 ℃/h.
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| CN114755977B (en) * | 2022-03-30 | 2024-08-16 | 威海光兴自动化设备有限责任公司 | 5-Axis Towpreg-winding programming method |
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