CN114147958A - Continuous fiber reinforced composite material with high fiber content and 3D printing method thereof - Google Patents
Continuous fiber reinforced composite material with high fiber content and 3D printing method thereof Download PDFInfo
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- CN114147958A CN114147958A CN202111180989.5A CN202111180989A CN114147958A CN 114147958 A CN114147958 A CN 114147958A CN 202111180989 A CN202111180989 A CN 202111180989A CN 114147958 A CN114147958 A CN 114147958A
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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
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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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
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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Abstract
The invention discloses a continuous fiber reinforced composite material with high fiber content and a 3D printing method thereof, and belongs to the crossing field of composite materials and additive manufacturing.
Description
Technical Field
The invention belongs to the crossing field of composite materials and additive manufacturing, relates to a rapid molding technology of a continuous fiber reinforced composite material, and particularly relates to a continuous fiber reinforced resin matrix composite material with high fiber content and a 3D printing method thereof.
Background
The continuous fiber reinforced resin matrix composite material has the advantages of high specific strength, high specific modulus, strong designability and the like, and is widely applied to the fields of aerospace, ships and submarines, automobile traffic, biomedical treatment, sports equipment and the like. The 3D printing technology of the continuous fiber reinforced thermoplastic composite material is a novel composite material manufacturing technology, and has attracted wide attention all over the world due to the advantages of simple and flexible process, high manufacturing precision, short manufacturing period, no need of expensive dies, capability of quickly forming complex components and the like.
Since the printing path directly affects the mechanical properties of the component, there have been many studies focusing on path planning for 3D printing of continuous fiber reinforced composites. The Shanghai university of traffic Zhao Donghua et al (CN107187056A) discloses a 3D printing method and system for complex parts based on curved surface layering, wherein a three-dimensional model is established according to the structure and curved surface characteristics of the complex parts, and structural lightweight topological optimization design and spatial 3D slicing layering are carried out, so that an optimized printing path is finally obtained, and the surface precision of the complex parts is effectively improved. Wangfuji et al (CN108891029A), university of great managerial engineering, discloses a planning method for 3D printing typical path of continuous fiber reinforced composite material, wherein a three-dimensional model is established, sliced and layered according to the actual size requirement of a forming member, a jumping point is accurately positioned and the jumping point action is completed by means of a jumping point processing mechanism, the printing path with the fewest breaking points is obtained, and the mechanical property of the continuous fiber reinforced composite material is ensured. The West' an traffic field Xiao Yong team (CN106980737A) discloses a manufacturing method of a continuous fiber reinforced composite material light structure, and develops a continuous fiber reinforced composite material light structure outline-internal core material lapping and internal core material complex-shaped cross lapping method to obtain an integrated continuous fiber reinforced composite material light structure. In addition, Nanjing aerospace university King peak display team (CN112046007A) discloses a multi-degree-of-freedom 3D printing path generation method for a continuous fiber reinforced resin matrix composite material. Beijing, Ministry of sciences and Innovation lightweight science research, Inc. (CN110001067A) utilizes finite element simulation technique to simulate stress distribution of components, and combines with fiber characteristics to plan a printing path capable of adjusting fiber orientation.
It is known that the volume content of continuous fibers directly affects the mechanical properties of the component, and increasing the volume content of the fibers contributes to further improving the overall properties of the component. Although the mechanical property and the forming precision of the continuous fiber reinforced resin matrix composite 3D printing component are improved to a certain extent due to the printing paths, the fiber volume content of the component cannot be improved due to the printing paths, and the mechanical property of the component cannot be further improved. Many studies also show that one of the main factors influencing continuous fiber 3D printing at present is how to increase the volume content of continuous fibers in a member (Chengming et al. review of research status of 3D printing continuous fiber reinforced composites. aeronautical reports). Therefore, it is significant to develop a continuous fiber 3D printing technology with high fiber content.
Disclosure of Invention
The invention provides a continuous fiber reinforced composite material with high fiber content and a 3D printing method thereof, aiming at solving the problems of low volume content of continuous fibers, weak interlayer binding force, poor mechanical property and the like in the existing printing method, improving the comprehensive performance of a 3D printing component and widening the application field of the 3D printing technology of the continuous fiber reinforced composite material.
The technical scheme adopted by the invention is as follows:
A3D printing method of a continuous fiber reinforced composite material with high fiber content comprises the following steps:
1) modeling by utilizing modeling software according to the size requirement of the component, layering by slicing software, processing jumping points and planning a continuous fiber reinforced composite material 3D printing path without a breakpoint by combining finite element analysis;
2) adjusting the starting positions of a new printing layer and an upper printing layer according to the size requirement of the component and the 3D printing path, and laying the fibers of a lower printing layer at the bonding position of the matrix resin of the upper layer through nearby dislocation by positive and negative half scanning intervals;
3) setting the printing layer height according to the properties of the fibers and the matrix resin, pressing the continuous fibers of the next layer into the matrix resin between the fibers of the previous layer, and performing staggered compaction;
4) repeating the steps 2) and 3), and performing layer-by-layer optimization on the 3D printing path to obtain a new 3D printing path;
5) setting the temperature of a hot bed, the printing speed and the temperature of a printing head according to the characteristics of continuous fibers and matrix resin, setting the printing scanning interval, the printing layer height and the laying speed by combining the diameter of the printing head and the fiber beam width, generating a G code required by a printing instrument by combining a new 3D printing path, simulating the printing process on a computer, and 3D printing the continuous fiber reinforced composite material after the simulation is completed.
Further, the printing layer height is set to 5% to 70%, preferably 20% to 50% of the original layer height.
Further, the continuous fiber is one or more of continuous carbon fiber, continuous aramid fiber, continuous ceramic fiber, continuous glass fiber and continuous silicon carbide fiber, or one of polypropylene fiber, ultra-high molecular weight polyethylene fiber and polyester fiber.
Further, the matrix resin is one or more of nylon, ABS resin, polylactic acid, polyamide, polyphenyl ether and polyether ether ketone resin, or one or more of epoxy resin, bismaleimide resin and cyanate ester.
Further, the print head temperature is set to be higher than the glass transition temperature of the matrix resin and lower than the decomposition temperature of the matrix resin, preferably 200 to 430 ℃.
Further, the printing speed is preferably 30 to 300 mm/min.
The continuous fiber reinforced composite material with high fiber content is obtained by performing 3D printing by adopting the method.
Compared with the prior art, the invention has the beneficial effects
(1) The printing method is obtained by adjusting and optimizing the existing mature 3D printing path, not only retains the advantages of the existing printing path, but also integrates the new staggered compaction technology according to the actual printing working condition, thereby obtaining the printing method with high fiber volume content
(2) The invention adopts the strategy of staggered compaction, optimizes the printing path, presses the fiber into the matrix resin of the previous layer of fiber and fiber, and compared with the traditional printing path, the volume content of the fiber can be improved by 25-100%; and the pressure of the printing head is far less than that of the direct printing of the same printing layer, so that the possibility of fiber damage and cutting is reduced.
(3) According to the special printing path designed by the invention, the printing head can compact the matrix resin between the fibers on the upper layer again, so that the matrix resin is melted again at high temperature, and the infiltration times between the matrix resin and the fibers and between the matrix resin and the matrix resin are increased, thereby improving the inter-line bonding force and the interlayer bonding force, and improving the comprehensive performance of the component.
(4) The new 3D printing path adopted by the invention can increase the fiber volume content in the component, improve the interface bonding mechanical property and reduce the porosity, so the invention has wider application range and can be applied to the fields of aerospace, automobile traffic, weaponry, biomedical treatment and the like.
Drawings
FIG. 1 is a schematic view of a standard tensile bar of unidirectional fiber reinforced resin matrix composite.
Fig. 2 is a schematic view of the arrangement of continuous fibers in the 3D printing path according to the present invention.
Fig. 3 is a schematic view of continuous fiber arrangement in a conventional 3D printing path.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.
The invention provides a 3D printing method of a continuous fiber reinforced composite material with high fiber content, which comprises the following steps:
1) according to the actual size requirement of the component, modeling is carried out by utilizing modeling software, layering is carried out by slicing software, jumping points are processed, and a continuous fiber reinforced composite material 3D printing path without a breakpoint, high quality, high efficiency and low defect is planned by combining finite element analysis;
2) adjusting the starting positions of a new printing layer and an upper printing layer by combining the size requirement of the component and the 3D printing path given in the step 1), and laying the fibers of the lower printing layer at the bonding position of the matrix resin of the upper layer by staggering positive and negative half scanning intervals nearby;
3) setting a proper printing layer height according to the properties of the fibers and the matrix resin, and pressing the continuous fibers into the matrix resin between the fibers of the previous layer, so that the printing effect of staggered compaction is realized, and the fiber volume content of the component is improved;
4) repeating the steps 2) and 3) to optimize the printing path in the step 1) layer by layer to obtain a new 3D printing path with high fiber volume content, low porosity and strong interface bonding force;
5) designing the temperature of a hot bed, the printing speed and the temperature of a printing head according to the characteristics of continuous fibers and matrix resin, designing the printing scanning interval, the printing layer height and the laying speed by combining the diameter of the printing head and the fiber beam width, generating a G code required by a printing instrument by combining a new 3D printing path, simulating the printing process on a computer, and 3D printing the continuous fiber reinforced composite material after the simulation is completed.
The staggered compaction is to compact the continuous fibers of the next layer into the matrix resin between the fibers of the previous layer as much as possible by adjusting the height of the printed layer, and the printed layer height may be set to be 5% to 70% (may be any value within this range, such as 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%), more preferably 20% to 50% (may be any value within this range, such as 20%, 25%, 30%, 35%, 40%, 45%, 50%) of the original layer height, in combination with the characteristics of the scanning pitch and the matrix resin.
The continuous fibers are one or more of continuous carbon fibers, continuous aramid fibers, continuous ceramic fibers, continuous glass fibers and continuous silicon carbide fibers, and can also be polypropylene fibers, ultrahigh molecular weight polyethylene fibers and polyester fibers, and also can be other continuous fiber tows prepared according to application requirements; the prepreg filaments containing continuous fibers prepared by combining the reinforcing fibers with different matrixes can also be used.
Wherein the matrix resin can be one or more of nylon, ABS resin, polylactic acid, polyamide, polyphenyl ether and polyether ether ketone resin; one or more of epoxy resin, bismaleimide resin, cyanate ester and other thermosetting resins may be used.
The temperature of the printing head is higher than the glass transition temperature of the matrix resin and lower than the decomposition temperature of the matrix resin, preferably 200-430 ℃ (which can be any value in the range, such as 200 ℃, 250 ℃, 300 ℃, 350 ℃, 400 ℃ and 430 ℃), the printing speed is matched with the printing temperature, so that the matrix resin contacted by the printing head is fully melted and the continuous fibers are smoothly pressed into the printing speed, and the printing speed is preferably 30-300 mm/min (which can be any value in the range, such as 30mm/min, 50mm/min, 100mm/min, 150mm/min, 200mm/min, 250mm/min and 300 mm/min).
In the following, an example is given, in which 3D printing is performed by using 1K continuous carbon fiber as a raw material of the reinforcing fiber, and 3D printing is performed by using nylon as a matrix resin raw material, by using the method for 3D printing of the continuous fiber reinforced composite material with a high fiber content proposed by the present invention. In this embodiment, standard tensile splines are 3D printed (see fig. 1), and the specific steps are as follows:
step 1: the conventional 3D printing path planning technology is utilized, modeling is carried out by utilizing modeling software according to the size requirement of a spline, layering is carried out by utilizing slicing software, jumping points are processed, finite element analysis is combined, and the continuous fiber reinforced composite material 3D printing conventional path without break points, high quality, high efficiency and low defects is planned. And setting the printing parameters as follows by combining the material property and the diameter of the printing nozzle: the printing speed is 100mm/min, the printing temperature is 280 ℃, the printing layer height is 0.4mm, the diameter of the matrix resin wire is 1.75mm, the matrix resin extrusion multiplying power is 100%, the scanning interval is 1mm, the temperature of the hot bed is 50 ℃, and the Chinese character 'hui' filling is adopted.
Step 2: and (3) adjusting the traditional path in the step (1), after the first layer is printed, positioning the next layer of initial printing point, manually modifying the G code to enable the printing head to move forwards by 0.5mm (half scanning distance), modifying the height parameter of the printed layer, reducing the height parameter by 50 percent, setting the height parameter as 0.2mm, and utilizing computer simulation to ensure that the layer of fibers is laid at the bonding position of the fibers of the upper layer and the matrix resin of the fibers.
And step 3: after the second layer is printed, positioning the next layer of initial printing point, manually modifying the G code to enable the printing head to move negatively by 0.5mm (half scanning distance), keeping the height of the printing layer to be 0.2mm, and utilizing computer simulation to ensure that the layer of fibers is laid at the bonding position of the fibers of the upper layer and the matrix resin of the fibers.
And 4, step 4: and (3) repeating the steps 2 and 3 until the printing height is specified, generating an optimized path code, and importing the path code into an instrument to complete printing to obtain a 3D printing standard spline with high fiber content (see figure 2).
The following is a comparative example, performed using a conventional 3D printing method of standard tensile splines.
The present comparative example substantially repeats the printing process in the above embodiment, except that only step 1 is used to obtain the conventional 3D printing path (see fig. 3), and no optimization is performed through steps 2-4, resulting in the standard tensile spline for conventional path printing.
As can be seen by comparing FIGS. 2 and 3, for the same part (e.g., the standard tensile bars shown in FIG. 1), the offset compaction strategy proposed by the present invention produces bars with significantly higher fiber content (a 67% theoretical increase) than the conventional path. And with the reduction of the printing layer height, the fiber volume content can be further improved, and a foundation is laid for the improvement of the mechanical property of the component.
The invention has been described in detail with reference to specific embodiments and illustrative examples, but the description is not intended to be construed in a limiting sense. Those skilled in the art will appreciate that various equivalent substitutions, modifications or improvements may be made to the technical solution of the present invention and its embodiments without departing from the spirit and scope of the present invention, which fall within the scope of the present invention. The scope of the invention is defined by the appended claims.
Claims (9)
1. A3D printing method of a continuous fiber reinforced composite material with high fiber content is characterized by comprising the following steps:
1) modeling by utilizing modeling software according to the size requirement of the component, layering by slicing software, processing jumping points and planning a continuous fiber reinforced composite material 3D printing path without a breakpoint by combining finite element analysis;
2) adjusting the starting positions of a new printing layer and an upper printing layer according to the size requirement of the component and the 3D printing path, and laying the fibers of a lower printing layer at the bonding position of the matrix resin of the upper layer through nearby dislocation by positive and negative half scanning intervals;
3) setting the printing layer height according to the properties of the fibers and the matrix resin, pressing the continuous fibers of the next layer into the matrix resin between the fibers of the previous layer, and performing staggered compaction;
4) repeating the steps 2) and 3), and performing layer-by-layer optimization on the 3D printing path to obtain a new 3D printing path;
5) setting the temperature of a hot bed, the printing speed and the temperature of a printing head according to the characteristics of continuous fibers and matrix resin, setting the printing scanning interval, the printing layer height and the laying speed by combining the diameter of the printing head and the fiber beam width, generating a G code required by a printing instrument by combining a new 3D printing path, simulating the printing process on a computer, and 3D printing the continuous fiber reinforced composite material after the simulation is completed.
2. The method of claim 1, wherein the print layer height is set to 5% to 70% of the original layer height.
3. The method of claim 2, wherein the print layer height is set to 20% to 50% of the original layer height.
4. The method of claim 1, wherein the continuous fibers are one or more of continuous carbon fibers, continuous aramid fibers, continuous ceramic fibers, continuous glass fibers, continuous silicon carbide fibers, or one of polypropylene fibers, ultra-high molecular weight polyethylene fibers, polyester fibers.
5. The method of claim 1, wherein the matrix resin is one or more of nylon, ABS resin, polylactic acid, polyamide, polyphenylene ether, polyetheretherketone resin, or one or more of epoxy resin, bismaleimide resin, cyanate ester.
6. The method of claim 1, wherein the printhead temperature is set above the glass transition temperature of the matrix resin and below the decomposition temperature of the matrix resin.
7. The method of claim 6, wherein the printhead temperature is 200-430 ℃.
8. The method according to claim 1, wherein the printing speed is preferably 30 to 300 mm/min.
9. A continuous fiber reinforced composite material with a high fiber content, characterized in that it is obtained by 3D printing using the method according to any one of claims 1 to 8.
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