CN114083811A - Integrated forming method for multi-surface complex composite shell containing boss - Google Patents
Integrated forming method for multi-surface complex composite shell containing boss Download PDFInfo
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- CN114083811A CN114083811A CN202111219043.5A CN202111219043A CN114083811A CN 114083811 A CN114083811 A CN 114083811A CN 202111219043 A CN202111219043 A CN 202111219043A CN 114083811 A CN114083811 A CN 114083811A
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- 239000002131 composite material Substances 0.000 title claims abstract description 102
- 238000000034 method Methods 0.000 title claims abstract description 65
- 239000004744 fabric Substances 0.000 claims abstract description 160
- 239000000835 fiber Substances 0.000 claims abstract description 127
- 239000003292 glue Substances 0.000 claims abstract description 33
- 229920005989 resin Polymers 0.000 claims abstract description 31
- 239000011347 resin Substances 0.000 claims abstract description 31
- 238000002347 injection Methods 0.000 claims abstract description 26
- 239000007924 injection Substances 0.000 claims abstract description 26
- 238000002360 preparation method Methods 0.000 claims abstract description 13
- 238000000465 moulding Methods 0.000 claims description 21
- 229920001187 thermosetting polymer Polymers 0.000 claims description 8
- 238000007789 sealing Methods 0.000 claims description 5
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 4
- 229920001567 vinyl ester resin Polymers 0.000 claims description 4
- 229920006231 aramid fiber Polymers 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 239000010453 quartz Substances 0.000 claims description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 2
- 239000000243 solution Substances 0.000 description 6
- 230000007547 defect Effects 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 238000001802 infusion Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000012945 sealing adhesive Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
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
- 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
- B29C70/342—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 using isostatic pressure
-
- 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
Abstract
The invention discloses an integrated forming method of a multi-surface complex composite shell containing a boss, which greatly reduces the number of breakpoints of a reinforced fiber fabric and obviously improves the structural performance of the multi-surface complex composite shell containing the boss through the design of a fiber fabric layering scheme; by designing the glue injection pipeline and the air exhaust pipeline, the conventional spiral pipe glue injection scheme is replaced, and the problems that glue injection short circuit occurs in the vacuum auxiliary preparation process, a large amount of resin is accumulated in the air exhaust pipe, the vacuum degree in the multi-surface complex composite material shell containing the boss is reduced and the like are solved; and the template on the air exhaust pipeline with the glue channel is adopted, so that redundant glue is prevented from directly entering the air exhaust pipeline, and the risk of glue injection failure is greatly reduced. In addition, the method of the invention also has the advantages of convenient operation and the like.
Description
Technical Field
The invention belongs to the technical field of composite material preparation, and particularly relates to a vacuum auxiliary preparation process of a multi-surface complex composite material shell containing a boss.
Background
At present, due to the complex structure and the more related planes, the multi-surface complex shell is mostly prepared and formed integrally by adopting metal materials or formed by adopting chopped fiber reinforced resin matrix composite materials through injection molding; the metal material has the defects of high manufacturing energy consumption, high possibility of being corroded by acid and alkali, seawater, salt mist and the like, poor environmental adaptability, high specific gravity and the like; the chopped fiber reinforced resin matrix composite material has the defects of low strength and modulus and the like. At present, the composite material shell prepared by the vacuum auxiliary process is mostly integrally paved by adopting plain weave fabrics, the paving process is suitable for a composite material flat plate structure or a simple shell structure, and a conventional paving mode is applied to the composite material shell containing the boss multi-surface complex composite material shell, so that a large number of fiber sections and fiber deformation conditions can appear in the shell forming process, and the structural performance of the composite material shell containing the boss multi-surface complex composite material shell is reduced.
At present, a glue injection pipeline is mostly formed by adopting spiral pipes in the composite material shell prepared by a vacuum auxiliary process, glue is injected into a composite material prefabricated part through gaps among the spiral pipes during glue injection, if the local pressure feeding of the spiral pipes or the closing of the gaps of the spiral pipes occurs, the glue can be injected into the prefabricated part slowly or not, the glue injection fails, and in addition, under the vacuum pressure, the spiral pipes can leave marks on a composite material blank, so that the appearance defect is caused.
Disclosure of Invention
The invention aims to solve the technical problem of providing an integrated molding method of a multi-surface complex composite shell containing a boss.
In order to solve the technical problems, the invention adopts the following technical scheme: the continuous fiber unidirectional fabrics are laid on the composite shell lower die, a boss-containing multi-face complex composite shell prefabricated part is formed by designing a 0 DEG/90 DEG orthogonal layering method between every two surfaces of the fiber unidirectional fabrics, a glue injection pipeline, an air suction pipeline and an upper template at an air suction position are scientifically arranged on the prefabricated part, and the integrated molding of the boss-containing multi-face complex composite shell is realized through a vacuum auxiliary pouring process.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which comprises the following steps:
1) selecting proper reinforced fiber fabric and thermosetting resin according to the performance requirement and the molding process requirement of the shell made of the multi-surface complex composite material containing the boss;
2) according to the structural size of a multi-surface complex composite shell containing a boss and an orthogonal layering method to be adopted, cutting a reinforced fiber fabric into a fiber unidirectional fabric I (0 degree), a fiber unidirectional fabric II (0 degree), a fiber unidirectional fabric III, a fiber unidirectional fabric IV (90 degrees) and a fiber unidirectional fabric V (90 degrees);
3) preparing a mould: the die comprises a lower die and an upper die plate; the lower die comprises a bottom plate and a lower die boss; the upper template corresponds to the lower template in structure and comprises a bottom plate and an upper template boss, and a flow channel which is through in the thickness direction and discontinuous in the length direction is arranged on the bottom plate around the upper template boss; carrying out wax stripping treatment on the surface of the lower die;
4) preparing a shell prefabricated part made of a boss-containing multi-surface complex composite material: the method adopts a unidirectional fiber orthogonal layering method, so that each two layers are a laying period, the splicing position of each layer is non-overlapped closed splicing, the splicing positions of adjacent layers are staggered, and the method comprises the following specific steps:
determining the 0-degree direction of the layer laying; laying a fiber unidirectional fabric I (0 degree) on the upper surface of the lower die in a non-planar area passing through a boss of the lower die along the direction of 0 degree of laying; laying a fiber unidirectional fabric II (0 degree) on the upper surface of the lower die in a plane area in a manner of clinging to the upper surface of the lower die; the two tail ends of the fiber unidirectional fabric I (0 degree) and the fiber unidirectional fabric II (0 degree) exceed the side wall surface closest to the boss by not less than 50 mm; paving a circle of fiber unidirectional fabric III on the side wall surface area of the boss by adopting a layering method in areas according to the structure;
second layer layering: determining the 90-degree direction of the layering; laying a fiber unidirectional fabric IV (90 degrees) on the surface of the first layer of laying along the direction of 0 degree of the laying, wherein the non-planar area passes through a boss of a lower die; in the plane area, a fiber unidirectional fabric V (90 degrees) is laid close to the surface of the first layer of the laying layer; two tail ends of the fiber unidirectional fabric IV (90 degrees) and the fiber unidirectional fabric V (90 degrees) exceed the side wall surface closest to the boss by not less than 50 mm;
the laying period is 0 degree/90 degree, and the rest period is laid according to the laying mode to finish the preparation of the shell prefabricated part of the multi-surface complex composite material containing the lug boss;
5) preparing a shell blank of the multi-face complex composite material containing the boss: the method adopts a vacuum auxiliary molding process to pour thermosetting resin into the prepared shell prefabricated member of the multi-surface complex composite material containing the boss, and comprises the following specific steps:
sequentially laying demolding cloth, a flow guide net, an upper template and a vacuum bag on the upper surface of the shell made of the multi-surface complex composite material and containing the boss from bottom to top; openings are formed at the positions of the demoulding cloth, the flow guide net, the upper template and the vacuum bag, which correspond to the upper surface of the lug boss of the lower mould, and an air exhaust port is arranged; opening a proper position of the vacuum bag corresponding to the runner of the upper template, and arranging a glue injection port;
sealing a vacuum bag on the lower mold bottom plate;
in a vacuum state, pouring thermosetting resin into a shell prefabricated part made of the multi-surface complex composite material containing the boss; after the resin is cured, the preparation of the shell blank of the multi-surface complex composite material containing the boss is finished;
6) demolding;
7) and (3) post-treatment: and (4) processing and finishing the shape according to the requirements of the product to obtain the multi-surface complex composite material shell containing the boss.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: the mould also comprises an exhaust seat layout plate; an opening is formed above the upper template boss; the structure of the exhaust seat layout plate is matched with the boss opening of the upper die plate, an opening for layout of an exhaust opening is arranged in the thickness direction, and a non-through groove in the thickness direction is arranged around the opening; the exhaust seat layout plate is embedded into the opening of the upper template. The structure can effectively avoid the phenomenon that the rubber solution is pumped into the air exhaust pipe to block the air exhaust pipeline in the air exhaust process of the vacuum auxiliary preparation process.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: the grooves of the exhaust seat layout plate comprise a main groove and a branch groove connected with the main groove.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: and the position of the extraction opening is provided with an opening of the flow guide net smaller than an opening of the demoulding cloth.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: the layering mode of the fiber unidirectional fabric I (0 degree), the fiber unidirectional fabric II (0 degree), the fiber unidirectional fabric IV (90 degrees) and the fiber unidirectional fabric V (90 degrees) is that the fiber unidirectional fabric I, the fiber unidirectional fabric II, the fiber unidirectional fabric IV (90 degrees) and the fiber unidirectional fabric V (90 degrees) are paved from the middle to two sides.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: and when the layering is carried out on the side wall surface of the boss in an area layering way by adopting a layering method in a divided area way, the upper part and the lower part of the reinforced fiber fabric can be cut and separated only when the height of the side wall surface of the boss is changed. Compared with the existing fiber laying scheme, the laying scheme has the advantages that the breaking points along the length direction of the fibers are the least, and therefore, the mechanical property of the product is the best.
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: the reinforced fiber fabric is one-way glass fiber fabric, one-way carbon fiber fabric, one-way aramid fiber fabric or one-way quartz fiber fabric
The invention relates to an integrated molding method of a multi-surface complex composite shell containing a boss, which is characterized by comprising the following steps: the thermosetting resin is vinyl ester resin, epoxy resin or unsaturated polyester resin.
According to the integrated forming method of the boss-containing multi-surface complex composite material shell, the number of breakpoints along the length direction of the fiber fabric during layering is greatly reduced through the design of the fiber fabric layering scheme, and the structural performance of the boss-containing multi-surface complex composite material shell is obviously improved. By designing the glue injection pipeline and the air exhaust pipeline, the conventional spiral pipe glue injection scheme is replaced, and the problems that the vacuum degree in the multi-surface complex composite material shell containing the boss is reduced, the glue injection is easy to fail and the like due to the fact that glue injection short circuit occurs and a large amount of resin is accumulated in the air exhaust pipe in the vacuum auxiliary preparation process are solved; by adopting the upper template of the air exhaust pipeline with the glue channel, the glue solution can flow into the flow channel firstly after being filled with the shell blank of the multi-surface complex composite material containing the lug boss, so that the glue solution is prevented from directly entering the air exhaust pipeline, and the risk of glue injection failure is greatly reduced. In addition, the method of the invention also has the advantages of convenient operation and the like.
Drawings
FIG. 1 is a schematic structural view of a multi-faced complex composite shell containing bosses according to the present invention;
FIG. 2 is a schematic structural view of a lower mold for a multi-faced complex composite shell with bosses according to the present invention;
FIG. 3 is a schematic representation of a unidirectional fabric ply of the present invention along the length of the lower mold;
FIG. 4 is a schematic representation of the layering of the unidirectional fabric of the present invention on the sidewall surface of a boss;
FIG. 5 is a schematic view of a unidirectional fabric ply of the present invention across the width of a lower mold;
FIG. 6 is a schematic view of the structure of the vacuum-assisted resin infusion process of the first embodiment;
FIG. 7 is a schematic diagram of a vacuum-assisted resin infusion process according to a second embodiment.
The method comprises the following steps of 1-a boss-containing multi-face complex composite material shell, 2-a lower die, 21-a lower die boss, 22-a lower die shallow groove, 23-a lower die deep groove, 24-a boss side wall face, 3-fiber unidirectional fabric I (0 degree), 4-fiber unidirectional fabric II (0 degree), 5-fiber unidirectional fabric III, 6-fiber unidirectional fabric IV (90 degree), 7-fiber unidirectional fabric V (90 degree), 8-demolding cloth, 9-a flow guide net, 10-an upper template, 11-a flow channel, 12-a glue injection port, 13-an air exhaust port, 14-an air exhaust seat cloth setting plate, 15-a vacuum bag and 16-a sealing rubber strip.
Detailed Description
The following examples further illustrate the proposed solution of the present invention, but should not be construed as limiting the technical solution. Any technical means which can achieve the invention form part of the technical solution according to the invention.
Example one
The multi-surface complex composite material shell 1 containing the boss of the present embodiment has a rectangular structure with a wall thickness of 5mm, and has a maximum dimension of 1200mm × 1100mm × 105mm, as shown in fig. 1. Four edges set up the rectangular channel respectively, and four rectangular channel outsides have formed two recesses, are the casing deep groove height respectively and are 100mm, and the width is 200mm, and the casing shallow groove height is 50mm, and the width is 100 mm.
When the shell 1 made of the boss-containing multi-surface complex composite material is prepared, a one-way fiber orthogonal layering method is adopted, so that each two layers are a laying period, the closed positions of adjacent layers are staggered, and the method comprises the following specific steps:
1) the reinforced fiber fabric is selected to have the surface density of 200g/m2The T700-grade carbon fiber unidirectional fabric is cut according to the overall dimension of the shell 1 of the multi-surface complex composite material with the lug bosses and is used for layering, and the table 1 shows.
TABLE 1 size of carbon fiber unidirectional fabric for multi-face complex composite material shell 1 containing boss
2) Preparing a mould: the mould comprises a lower mould 2, an upper mould plate 10 and an air exhaust seat arrangement plate 14. The lower die 2 comprises a bottom plate and four lower die bosses 21, and a lower die shallow groove 22 and a lower die deep groove 23 are formed among the four lower die bosses 21; the cope match-plate pattern 10, the structure is corresponding with lower mould 2, the material is polypropylene, thickness is 6mm, including bottom plate and four cope match-plate pattern bosss, the 5 mm's of the wide field font of four cope match-plate pattern boss processing link up runner 11 on the bottom plate, in the mouth font of runner 11 is peripheral, leave eight wide 10 mm's connecting strip, be used for avoiding cope match-plate pattern 10 bottom plate to be cut apart into independent two parts by runner 11, eight connecting strip are located the cross in the middle of runner 11 respectively and the crossing both sides 200mm department of position of outlying mouth font, set up 240 mm's opening in cope match-plate pattern boss central point position. The exhaust seat layout plate 14 is of a flat plate structure with the thickness of 6mm, the size is 240mm multiplied by 240mm, an opening with the diameter of 30mm is arranged at the center, a trunk groove with the width of 2mm and the depth of 5mm is formed in the opening, five pairs of branch grooves with the width of 2mm and the depth of 5mm are formed in two sides of the trunk groove and are in through connection with the trunk groove, and the distance between the tail ends of the branch grooves and the adjacent boundary is 20 mm. The exhaust seat layout plate 14 is inserted into the opening at the center of the boss of the upper die plate as shown in fig. 6. The lower die 2 is processed with demolding wax for 3 times for standby;
3) preparing a prefabricated part of a shell 1 made of a boss-containing multi-surface complex composite material:
first layer laying: the length direction of the lower die 2 is the direction of 0 degree of the layering.
A layer of fiber unidirectional fabric I (0 degree) 3 is respectively paved clinging to the surface of the lower die 2 along the direction of 0 degree of paving, and as shown in figure 3, the paving width is consistent with the width of a boss 21 of the lower die. During layering, the center of the width direction of the shallow groove 22 of the lower die is taken as a layering original point, the center of the length direction of the fiber unidirectional fabric I (0 degree) 3 is overlapped with the layering original point, layering is carried out towards two sides, the fiber unidirectional fabric spans the boss 21 of the lower die, then the fiber unidirectional fabric continuously extends outwards for 50mm along the surface of the bottom plate of the lower die 2, and the redundant fabric is cut and removed as shown in fig. 3. When the layers are laid, the fiber fabrics are compacted at the corners, so that the condition that the fiber fabrics are suspended is avoided.
And (3) laying a layer of fiber unidirectional fabric II (0 degree) 4 along the direction of 0 degree of the laying layer and closely attached to the surface of the deep groove 23 of the lower die, as shown in figure 3. When laying, the original point of the laying is also positioned at the center of the width direction of the shallow groove 22 of the lower die, the center of the length direction of the fiber unidirectional fabric II (0 degree) 4 is superposed with the original point of the laying, the laying is carried out towards two sides, and two tail ends of the fiber unidirectional fabric II (0 degree) 4 are flush with the fiber unidirectional fabric I (0 degree) 3, as shown in fig. 3.
And a layer of fiber unidirectional fabric III 5 is laid along the fiber direction and is tightly attached to the side wall surface 24 of the boss. When the fiber unidirectional fabric is laid, any position of the outer wall surface 24 of the boss is selected as a laying starting point, the height of the outer wall surface 24 of the boss is changed, namely the inner and outer ports of the shallow groove 22 of the lower die, the fiber unidirectional fabric III 5 is bound to the bottom surface of the shallow groove 22 of the lower die, the upper half part of the fiber unidirectional fabric surrounds the single lower die boss 21 to form a closed state, and the lower half part of the fiber unidirectional fabric is continuously laid with a constant width until the lower half part of the fiber unidirectional fabric extends into the position 200mm below the adjacent lower die boss 21; when the outer wall surfaces of the adjacent lower die bosses 21 are paved, the fiber unidirectional fabric III 5 is cut according to the size of the area where the fiber unidirectional fabric III 5 is paved, the boundary of the two is closed, but the two are not overlapped, and the fiber unidirectional fabric III is cut off as shown in FIG. 4. Because the unidirectional fabric is adopted, the laying mode separated from the width direction does not influence the mechanical property of the fiber.
Second layer layering: the width direction of the lower die 2 is the 90-degree direction of the layering.
A layer of fiber unidirectional fabric IV (90 degrees) 6 is laid along the 90-degree direction of the laying layer and closely attached to the surface of the first layer of the laying layer, and as shown in figure 5, the width of the laying layer is consistent with the length of a boss 21 of the lower die. During layering, the center of the deep groove 23 of the lower die in the width direction is taken as a layering original point, the center of the fiber unidirectional fabric IV (90 degrees) 6 in the length direction is overlapped with the layering original point, layering is carried out towards two sides, the fiber unidirectional fabric spans the boss 21 of the lower die, then the fiber unidirectional fabric continuously extends outwards for 50mm along the surface of the bottom plate of the lower die 2, and the redundant fabric is cut and removed as shown in FIG. 5. When the layers are laid, the fiber fabrics are compacted at the corners, so that the condition that the fiber fabrics are suspended is avoided.
A layer of fibrous unidirectional fabric V (90) 7 is laid against the first ply surface at 90 deg. of the ply as shown in FIG. 5. When laying, the laying origin is also positioned at the center of the deep groove 23 of the lower die in the width direction, the center of the length direction of the fiber unidirectional fabric V (90 degrees) 7 is superposed with the laying origin, laying is carried out towards two sides, two tail ends of the fiber unidirectional fabric V (90 degrees) 7 are flush with the fiber unidirectional fabric IV (90 degrees) 6, and the laying mode is shown in figure 5.
The laying period is 0 degree/90 degrees. And (3) paving for 10 periods according to the paving mode to finish the preparation of the prefabricated part of the multi-surface complex composite material shell 1 containing the lug boss.
4) By utilizing a vacuum auxiliary forming process, vinyl ester resin is poured into a prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss:
laying a demoulding cloth 8 above the prefabricated part of the multi-surface complex composite material shell 1 containing the lug boss, wherein the outline dimension of the demoulding cloth is 50mm larger than that of the prefabricated part of the multi-surface complex composite material shell 1 containing the lug boss; the release fabric 8 is cut into a square opening of 250mm × 250mm at a position corresponding to the center of the lower mold boss 21 of the lower mold 2.
The flow guide net 9 is laid on the upper surface of the demoulding cloth 8 in the same arrangement mode, the opening size of the flow guide net 9 is 240mm multiplied by 240mm, the flow guide net 9 is positioned at the center of the opening of the demoulding cloth 8, the size of the flow guide net is smaller than the opening size of the demoulding cloth 8, and the flow guide net 9 can be prevented from being stuck on the surface of the boss-containing multi-surface complex composite material shell 1 blank by resin.
An upper template 10 is arranged on the upper surface of the flow guide net 9, and glue injection ports 12 are arranged at the intersections of each flow channel 11, as shown in fig. 6.
An air suction seat arrangement plate 14 is arranged at the opening position of the upper template 10, and an air suction opening 13 is arranged at the opening position. The purpose of arranging the exhaust seat layout plate 14 is to fill the gap of the exhaust seat layout plate 14 with excess resin before the resin is not cured and then pump the resin into the exhaust pipeline after the resin is impregnated with the prefabricated part of the boss-containing multi-surface complex composite material shell 1, so that the grease-rich area of the prefabricated part of the boss-containing multi-surface complex composite material shell 1 can be effectively reduced.
And air suction ports 13 are distributed at the opening positions of the demoulding cloth 8, the flow guide net 9 and the air suction seat distribution plate 14.
Sealing the prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss on the lower die 2 by using a vacuum bag 15 adhered with a sealing adhesive tape 16; and (3) opening the exhaust pipe, and injecting vinyl ester resin into the prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss through the runner 11 through the glue injection port 12 of the vacuum glue injection system after the vacuum degree reaches-0.095 MPa, so that the resin in the glue injection pipeline is ensured to be uninterrupted in the whole glue injection process, wherein the vacuum system is shown in figure 6. And after the pouring is finished, keeping the vacuum for 6h, and after the resin is cured, closing the vacuum pump to finish the preparation of the blank of the multi-surface complex composite material shell 1 containing the boss.
8) And (6) demolding. And (3) performing a demoulding process after the resin is cured, and taking the boss-containing multi-surface complex composite material shell 1 blank from the lower die 2 to finish the demoulding process of the boss-containing multi-surface complex composite material shell 1 blank.
9) And (5) post-treatment. And (3) processing and finishing the shape according to the product requirements to obtain the shell 1 made of the multi-surface complex composite material containing the boss.
The shell 1 blank made of the multi-surface complex composite material containing the boss is integrally formed, and is good in structural performance and low in process cost.
Example two
The difference from the first embodiment is that:
preparing a shell 1 prefabricated part made of a boss-containing multi-surface complex composite material, and when laying is carried out on a boss side wall surface 24 of a first layer of laying, cutting and separating a fiber unidirectional fabric III 5 up and down by taking the bottom surface of a lower mold shallow groove 22 as a boundary, wherein the upper half part is closed around a single lower mold boss 21, and the lower half part is closed around two lower mold bosses 21 at two sides of the lower mold shallow groove 22.
EXAMPLE III
The complex combined material casing 1 of boss multiaspect that contains of this embodiment is 8 mm's rectangular structure, and the maximum dimension of outline is 1500mm 1300mm 208mm, and four edges set up the rectangular channel respectively, and four rectangular channels outsides have formed two the same recesses, and the recess height is 200mm, and the width is 200 mm.
When the shell 1 made of the boss-containing multi-surface complex composite material is prepared, a one-way fiber orthogonal layering method is adopted, so that each two layers are a laying period, the splicing positions of adjacent layers are staggered, and the method comprises the following specific steps:
1) the reinforced fiber fabric is selected to have the surface density of 200g/m2The EWR200 glass fiber unidirectional fabric of (1) was cut out according to the overall size of the complex composite material shell 1 having a plurality of surfaces with bosses, and was used for layering, as shown in table 1.
TABLE 1 size of glass fiber unidirectional fabric for boss-containing multi-face complex composite material shell 1
2) Preparing a mould: the mold includes a lower mold 2 and an upper mold plate 10. The lower die 2 comprises a bottom plate and four lower die bosses 21, and a lower die shallow groove 22 and a lower die deep groove 23 are formed among the four lower die bosses 21; the upper die plate 10 is structurally corresponding to the lower die 2, is made of polypropylene and is 6mm thick, and comprises a bottom plate and four upper die plate bosses, wherein a Chinese character 'tian' -shaped through flow channel 11 with the width of 4mm is processed on the bottom plate around the four upper die plate bosses. The lower die 2 is processed with demolding wax for 3 times for standby;
3) preparing a prefabricated part of a shell 1 made of a boss-containing multi-surface complex composite material:
first layer laying: the length direction of the lower die 2 is the direction of 0 degree of the layering.
A layer of fiber unidirectional fabric I (0 degree) 3 is laid on the surface of the lower die 2 along the direction of 0 degree of laying, and the width of the laying is consistent with that of a boss 21 of the lower die at two positions shown in figure 3. When laying, taking the center of the width direction of the shallow groove 22 of the lower die as a laying original point, overlapping the center of the length direction of the fiber unidirectional fabric I (0 degree) 3 with the laying original point, laying the fabric to two sides, crossing the boss 21 of the lower die, continuing extending the fabric outwards for 60mm along the surface of the bottom plate of the lower die 2, and cutting off the redundant fabric. When the layers are laid, the fiber fabrics are compacted at the corners, so that the condition that the fiber fabrics are suspended is avoided.
And (3) laying a layer of fiber unidirectional fabric II (0 degree) 4 along the direction of 0 degree of the laying layer and closely attached to the surface of the deep groove 23 of the lower die, as shown in figure 3. When laying, the original point of the laying is also positioned at the center of the width direction of the groove 22, the center of the length direction of the fiber unidirectional fabric II (0 degree) 4 is superposed with the original point of the laying, the laying is carried out towards two sides, and two tail ends of the fiber unidirectional fabric II (0 degree) 4 are flush with the fiber unidirectional fabric I (0 degree) 3, as shown in fig. 3.
And a layer of fiber unidirectional fabric III 5 is laid along the fiber direction and is tightly attached to the side wall surface 24 of the boss. When laid, the fibrous unidirectional fabric iii 5 forms a closure around all the lower mould bosses 21.
Second layer layering: the width direction of the lower die 2 is the 90-degree direction of the layering.
A layer of fiber unidirectional fabric IV (90 degrees) 6 is laid along the 90-degree direction of the laying layer and closely attached to the surface of the first layer of the laying layer, and as shown in figure 5, the width of the laying layer is consistent with the length of a boss 21 of the lower die. During layering, the center of the deep groove 23 of the lower die in the width direction is taken as a layering original point, the center of the fiber unidirectional fabric IV (90 degrees) 6 in the length direction is overlapped with the layering original point, layering is carried out towards two sides, the fiber unidirectional fabric spans the boss 21 of the lower die, then the fiber unidirectional fabric continuously extends outwards for 60mm along the surface of the bottom plate of the lower die 2, and the redundant fabric is cut and removed as shown in FIG. 5. When the layers are laid, the fiber fabrics are compacted at the corners, so that the condition that the fiber fabrics are suspended is avoided.
A layer of fibrous unidirectional fabric V (90) 7 is laid against the first ply surface at 90 deg. of the ply as shown in FIG. 5. When laying, the laying origin is also positioned at the center of the width direction of the groove 23, the center of the length direction of the fiber unidirectional fabric V (90 degrees) 7 is superposed with the laying origin, laying is carried out towards two sides, two tail ends of the fiber unidirectional fabric V (90 degrees) 7 are flush with the fiber unidirectional fabric IV (90 degrees) 6, and the laying mode is shown in figure 5.
The laying period is 0 degree/90 degrees. And (3) paving the composite material shell for 16 periods according to the paving mode to finish the preparation of the prefabricated part of the multi-surface complex composite material shell 1 containing the lug boss.
4) The unsaturated polyester resin is poured into the prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss by utilizing a vacuum auxiliary forming process:
and (3) paving demoulding cloth 8 on the upper surface of the prefabricated part of the multi-surface complex composite material shell 1 containing the boss, wherein the overall dimension of the demoulding cloth is 50mm larger than that of the prefabricated part of the multi-surface complex composite material shell 1 containing the boss. At the corresponding position of the central position of each lower die boss 21, the release cloth 8 is cut into a square opening of 300mm × 300 mm.
The flow guide net 9 is laid on the upper surface of the demoulding cloth 8 in the same arrangement mode, the opening size of the flow guide net 9 is 280mm multiplied by 280mm, the flow guide net 9 is positioned at the center of the opening of the demoulding cloth 8, the size of the flow guide net is smaller than the opening size of the demoulding cloth 8, and the flow guide net 9 can be prevented from being stuck on the surface of the prefabricated member of the multi-surface complex composite material shell 1 with the lug bosses.
An upper template 10 is laid on the upper surface of the flow guiding net 9, and glue injection ports 12 are arranged at the intersections of each flow channel 11, as shown in fig. 7.
And air suction ports 13 are distributed at the opening positions of the demoulding cloth 8, the flow guide net 9 and the upper template 10.
Sealing the prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss on the lower die 2 by using a vacuum bag 15 adhered with a sealing adhesive tape 16; and (3) opening the exhaust pipe, and injecting unsaturated polyester resin into the prefabricated part of the shell 1 made of the multi-surface complex composite material containing the boss through the runner 11 through the glue injection port 12 of the vacuum glue injection system after the vacuum degree reaches-0.095 MPa, so that the resin in the glue injection pipeline is ensured to be uninterrupted in the whole glue injection process, wherein the vacuum system is shown in a figure 7. And after the pouring is finished, keeping the vacuum for 6h, and after the resin is cured, closing the vacuum pump to finish the preparation of the blank of the multi-surface complex composite material shell 1 containing the boss.
8) Demolding: and (3) performing a demoulding process after the resin is cured, and taking the boss-containing multi-surface complex composite material shell 1 blank from the lower die to finish the demoulding process of the boss-containing multi-surface complex composite material shell 1 blank.
9) And (5) post-treatment. And (3) processing and finishing the shape according to the product requirements to obtain the shell 1 made of the multi-surface complex composite material containing the boss.
The shell 1 blank made of the multi-surface complex composite material containing the boss is integrally formed, and is good in structural performance and low in process cost.
Claims (8)
1. An integrated forming method of a multi-surface complex composite shell containing a boss comprises the following steps:
1) selecting proper reinforced fiber fabric and thermosetting resin according to the performance requirement and the molding process requirement of the shell (1) made of the multi-surface complex composite material containing the boss;
2) according to the structural size of a boss-containing multi-face complex composite shell (1) and an orthogonal layering method to be adopted, cutting a reinforced fiber fabric into a fiber unidirectional fabric I (0-degree (3)), a fiber unidirectional fabric II (0-degree (4)), a fiber unidirectional fabric III (5), a fiber unidirectional fabric IV (90-degree (6)) and a fiber unidirectional fabric V (90-degree (7));
3) preparing a mould: the die comprises a lower die (2) and an upper die plate (10); the lower die (2) comprises a bottom plate and a lower die boss (21); the upper die plate (10) corresponds to the lower die (2) in structure and comprises a bottom plate and an upper die plate boss, and a flow channel (11) which is through in the thickness direction and discontinuous in the length direction is arranged on the bottom plate around the upper die plate boss; demolding wax treatment is carried out on the surface of the lower mold (2);
4) preparing a prefabricated part of the shell (1) made of the boss-containing multi-surface complex composite material: the method adopts a unidirectional fiber orthogonal layering method, so that each two layers are a laying period, the splicing position of each layer is non-overlapped closed splicing, the splicing positions of adjacent layers are staggered, and the method comprises the following specific steps:
determining the 0-degree direction of the layer laying; laying a fiber unidirectional fabric I (0 degree to 3 degree) on the upper surface of the lower die (2) in a non-planar area passing through a boss (21) of the lower die along the direction of 0 degree of laying; in the plane area, a fiber unidirectional fabric II (0 degree to 4 degree) is laid on the upper surface of the lower die (2) in a clinging manner; the two ends of the fiber unidirectional fabric I (0 degree) (3) and the fiber unidirectional fabric II (0 degree) (4) exceed the side wall surface (24) closest to the boss by not less than 50 mm; in the area of the side wall surface (24) of the boss, a circle of fiber unidirectional fabric III (5) is paved by adopting a layering method in different areas according to the structure;
second layer layering: determining the 90-degree direction of the layering; laying a fiber unidirectional fabric IV (90 degrees) (6) on the surface of the first layer of the laying layer along the direction of 0 degree of the laying layer and in a non-planar area passing through a boss (21) of the lower die; in the plane area, a fiber unidirectional fabric V (90 degrees) (7) is laid close to the surface of the first layer of the laying layer; the two tail ends of the fiber unidirectional fabric IV (90 degrees) (6) and the fiber unidirectional fabric V (90 degrees) (7) exceed the side wall surface (24) closest to the boss by not less than 50 mm;
the laying period is 0 degree/90 degree, and the rest period is laid according to the laying mode to finish the preparation of the prefabricated part of the shell (1) made of the multi-surface complex composite material containing the boss;
5) preparing a blank of the shell (1) made of the multi-surface complex composite material containing the boss: the method adopts a vacuum auxiliary molding process to pour thermosetting resin into the prepared prefabricated part of the shell (1) made of the multi-surface complex composite material containing the boss, and comprises the following specific steps:
sequentially laying demolding cloth (8), a flow guide net (9), an upper template (10) and a vacuum bag (15) on the upper surface of the shell (1) made of the multi-surface complex composite material and provided with the boss from bottom to top; openings are formed at the positions of the demoulding cloth (8), the flow guide net (9), the upper template (10) and the vacuum bag (15) corresponding to the upper surface of the lower mould boss (21), and an air suction opening (13) is arranged; an opening is formed in the vacuum bag (15) at a proper position corresponding to the runner (11) of the upper template (10), and a glue injection port (12) is arranged;
sealing the vacuum bag (15) on the bottom plate of the lower mould (2);
in a vacuum state, pouring thermosetting resin into a prefabricated part of a shell (1) made of the multi-surface complex composite material containing the boss; after the resin is cured, the preparation of the blank of the shell (1) made of the multi-surface complex composite material containing the boss is finished;
6) demolding;
7) and (3) post-treatment: and (3) processing and finishing the shape according to the requirements of the product to obtain the shell (1) made of the multi-surface complex composite material containing the lug boss.
2. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: the mould also comprises an exhaust seat layout plate (14); an opening is arranged above the lug boss of the upper template (10); the structure of the exhaust seat layout plate (14) is matched with the boss opening of the upper template, an opening for layout of the exhaust opening (13) is arranged in the thickness direction, and a non-through groove in the thickness direction is arranged around the opening; the exhaust seat layout plate (14) is embedded in the opening of the upper template (10).
3. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 2, wherein: the grooves of the exhaust seat layout plate (14) comprise a main groove and a branch groove connected with the main groove.
4. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: and the position provided with the air suction opening (13) is smaller than the opening of the demolding cloth (8) by the opening of the flow guide net (9).
5. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: the layering mode of the fiber unidirectional fabric I (0 degree) (3), the fiber unidirectional fabric II (0 degree) (4), the fiber unidirectional fabric IV (90 degree) (6) and the fiber unidirectional fabric V (90 degree) (7) is that the fiber unidirectional fabric I, the fiber unidirectional fabric II, the fiber unidirectional fabric IV and the fiber unidirectional fabric V are paved from the middle to two sides.
6. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: by adopting a split-area layering method, when the side wall surface (24) of the boss is layered in an area mode, the upper portion and the lower portion of the reinforced fiber fabric can be cut and separated only when the height of the side wall surface (24) of the boss changes.
7. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: the reinforced fiber fabric is a unidirectional glass fiber fabric, a unidirectional carbon fiber fabric, a unidirectional aramid fiber fabric or a unidirectional quartz fiber fabric.
8. The integrated molding method of the boss-containing multi-faced complex composite shell as claimed in claim 1, wherein: the thermosetting resin is vinyl ester resin, epoxy resin or unsaturated polyester resin.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111219043.5A CN114083811A (en) | 2021-10-20 | 2021-10-20 | Integrated forming method for multi-surface complex composite shell containing boss |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TW200808539A (en) * | 2006-08-02 | 2008-02-16 | xue-xia Lin | Manufacturing method for case with woven fiber texture |
| US20080233342A1 (en) * | 2004-07-20 | 2008-09-25 | Michael Ian Birrell | Recyclable Composite Plastic for Automotive Headliner |
| CN105109060A (en) * | 2015-09-17 | 2015-12-02 | 江苏恒神股份有限公司 | Vacuum assisted resin injection process for preparing fiber composite material |
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2021
- 2021-10-20 CN CN202111219043.5A patent/CN114083811A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080233342A1 (en) * | 2004-07-20 | 2008-09-25 | Michael Ian Birrell | Recyclable Composite Plastic for Automotive Headliner |
| TW200808539A (en) * | 2006-08-02 | 2008-02-16 | xue-xia Lin | Manufacturing method for case with woven fiber texture |
| CN105109060A (en) * | 2015-09-17 | 2015-12-02 | 江苏恒神股份有限公司 | Vacuum assisted resin injection process for preparing fiber composite material |
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