CN114147958B - High-fiber-content continuous fiber reinforced composite material and 3D printing method thereof - Google Patents
High-fiber-content continuous fiber reinforced composite material and 3D printing method thereof Download PDFInfo
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- CN114147958B CN114147958B CN202111180989.5A CN202111180989A CN114147958B CN 114147958 B CN114147958 B CN 114147958B CN 202111180989 A CN202111180989 A CN 202111180989A CN 114147958 B CN114147958 B CN 114147958B
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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
Abstract
The invention discloses a continuous fiber reinforced composite material with high fiber content and a 3D printing method thereof, belonging to the crossing field of composite material and additive manufacturing.
Description
Technical Field
The invention belongs to the crossing field of composite material and additive manufacturing, relates to a rapid molding technology of a continuous fiber reinforced composite material, and in particular 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 various fields such as aerospace, ship submarines, automobile traffic, biomedical treatment, sports equipment and the like. The continuous fiber reinforced thermoplastic composite material 3D printing technology is a novel composite material manufacturing technology, and has attracted wide attention worldwide because of the advantages of simple and flexible technological process, high manufacturing precision, short period, no need of expensive dies, capability of rapidly 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 and the like (CN 107187056A) disclose a 3D printing method and system for complex parts based on curved surface layering, wherein a three-dimensional model of the complex parts is built according to the structure and curved surface characteristics of the complex parts, and the structure is light-weight, topological optimization design and space 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. University of company Wang Fuji et al (CN 108891029A) discloses a planning method for 3D printing of a typical path of a continuous fiber reinforced composite material, wherein a three-dimensional model is established according to the actual size requirement of a forming member, slicing and layering are carried out, a jumping point is accurately positioned by means of a jumping point processing mechanism, the jumping point action is completed, the printing path with the least breaking points is obtained, and the mechanical property of the continuous fiber reinforced composite material is ensured. The Tian Xiaoyong team of the western traffic university (CN 106980737A) discloses a manufacturing method of a continuous fiber reinforced composite light structure, and develops a continuous fiber reinforced composite light structure contour-inner core material lap joint and inner core material complex shape cross lap joint method to obtain an integrated continuous fiber reinforced composite light structure. In addition, wang Xianfeng team (CN 112046007A) of Nanjing aviation aerospace university discloses a method for generating a multi-degree-of-freedom 3D printing path of a continuous fiber reinforced resin matrix composite material. The Beijing machine department national institute of light weight sciences, inc. Shan Zhongde et al (CN 110001067A) uses finite element simulation techniques to simulate the stress distribution of the component and combines the fiber characteristics to plan a print path that can be targeted for fiber orientation adjustment.
It is well known that the volume content of continuous fibers directly affects the mechanical properties of the component, and that increasing the volume content of fibers helps to further increase the overall properties of the component. Although the occurrence of the printing paths improves the mechanical property and the forming precision of the continuous fiber reinforced resin matrix composite 3D printing component to a certain extent, the printing paths can not improve the fiber volume content of the component and can not further improve the mechanical property of the component. Several studies have also shown that one of the major factors currently affecting 3D printing of continuous fibers is how to increase the volume content of continuous fibers in a component (Chen Xiangming et al. 3D printed continuous fiber reinforced composite research status reviews. Aviation journal). Therefore, the development of a continuous fiber 3D printing technology with high fiber content is significant.
Disclosure of Invention
In order to solve the problems of low volume content of continuous fibers, weak interlayer bonding force, poor mechanical property and the like in the existing printing method, the invention improves the comprehensive performance of a 3D printing member, widens the application field of a 3D printing technology of a continuous fiber reinforced composite material, and provides a continuous fiber reinforced composite material with high fiber content and a 3D printing method thereof.
The technical scheme adopted by the invention is as follows:
a method for 3D printing of a high fiber content continuous fiber reinforced composite material, comprising the steps of:
1) Modeling by modeling software according to the component size requirement, layering by slicing software, processing jump points and combining finite element analysis to plan a 3D printing path of the continuous fiber reinforced composite material without break points;
2) Adjusting the initial positions of the new printing layer and the upper printing layer by combining the component size requirement and the 3D printing path, and laying the fibers of the lower printing layer at the bonding position of the matrix resin of the upper layer by misplacing the adjacent positive and negative half scanning intervals;
3) Setting the height of a printing layer 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 carrying out dislocation compaction;
4) Repeating the steps 2) and 3), and optimizing the 3D printing path layer by layer to obtain a new 3D printing path;
5) According to the characteristics of continuous fibers and matrix resin, the temperature of a hot bed, the printing speed and the temperature of a printing head are set, the printing scanning interval, the printing layer height and the spinning speed are set by combining the diameter of the printing head and the width of a fiber bundle, the G code required by a printing instrument is generated by combining a new 3D printing path, the printing process is simulated on a computer, and after the simulation is finished, the continuous fiber reinforced composite material is 3D printed.
Further, the printing layer height is set to 5% -70% of the original layer height, preferably 20% -50%.
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.
Further, the temperature of the print head 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 300mm/min.
A continuous fiber reinforced composite material with high fiber content is obtained by adopting the method to carry out 3D printing.
Compared with the prior art, the invention has the beneficial effects that
(1) The invention is obtained by adjusting and optimizing the existing mature 3D printing path, not only maintains the advantages of the existing printing path, but also merges the new dislocation compaction technology according to the actual printing working condition, thereby obtaining the printing method with high fiber volume content
(2) The invention adopts a staggered compaction strategy, optimizes the printing path, presses the fiber into the fiber of the upper layer and the matrix resin of the fiber, and can improve the volume content of the fiber by 25 to 100 percent compared with the traditional printing path; and the pressure of the printing head is far smaller than the pressure of direct printing with the same printing layer height, so that the possibility of damaging and cutting the fiber is reduced.
(3) According to the special printing path designed by the invention, the printing head can compact the matrix resin between the upper layer of fibers again, so that the matrix resin is melted again at high temperature, the infiltration times between the matrix resin and the fibers and between the matrix resin and the matrix resin are increased, and therefore, the bonding force between wires and the bonding force between layers are improved, and the comprehensive performance of the component is improved.
(4) The novel 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 that the invention has wider application range and can be applied to various fields such as aerospace, automobile traffic, weaponry, biomedical treatment and the like.
Drawings
FIG. 1 is a schematic illustration of a standard tensile spline of a unidirectional fiber reinforced resin matrix composite.
Fig. 2 is a schematic diagram of continuous fiber arrangement in a 3D printing path according to the present invention.
Fig. 3 is a schematic diagram of a continuous fiber arrangement under a conventional 3D printing path.
Detailed Description
The technical solutions 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) Modeling by modeling software and layering by slicing software according to the actual size requirement of the component, processing jump points and combining finite element analysis to plan a continuous fiber reinforced composite material 3D printing path without break points, high quality, high efficiency and low defects;
2) Adjusting the initial positions of the new printing layer and the upper printing layer by combining the component size requirement 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 misplacing the adjacent positive and negative half scanning intervals;
3) Setting a proper printing layer height according to the properties of the fibers and the matrix resin, pressing the continuous fibers into the matrix resin between the fibers of the upper layer, realizing the printing effect of staggered compaction, and improving the fiber volume content of the component;
4) Repeating the steps 2) and 3) optimizing 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 binding force;
5) According to the characteristics of continuous fibers and matrix resin, the temperature of a hot bed, the printing speed and the temperature of a printing head are designed, the printing scanning interval, the printing layer height and the spinning speed are designed by combining the diameter of the printing head and the width of a fiber bundle, the G code required by a printing instrument is generated by combining a new 3D printing path, the printing process is simulated on a computer, and after the simulation is finished, the continuous fiber reinforced composite material is 3D printed.
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 printing layer, and the printing layer height can be set to be 5% -70% (can be any value in the range, such as 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%) of the original layer height, more preferably 20% -50% (can be any value in the range, such as 20%, 25%, 30%, 35%, 40%, 45%, 50%) by combining the scanning interval and the characteristics of the matrix resin.
Wherein 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, polypropylene fiber, ultra-high molecular weight polyethylene fiber, polyester fiber, and other continuous fiber tows prepared according to application requirements; the continuous fiber-containing prepreg filaments prepared from the reinforcing fibers and 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; and may be one or more of epoxy resin, bismaleimide resin, cyanate ester and other thermosetting resins.
Wherein the temperature of the print head is higher than the glass transition temperature of the matrix resin used and lower than the decomposition temperature of the matrix resin used, preferably 200-430 ℃ (which may be any value within the range, for example 200 ℃, 250 ℃, 300 ℃, 350 ℃, 400 ℃, 430 ℃), the printing rate should be matched to the printing temperature so that the matrix resin contacted by the print head is sufficiently melted, and the continuous fibers are smoothly pressed into it, preferably 30-300 mm/min (which may be any value within the range, for example 30mm/min, 50mm/min, 100mm/min, 150mm/min, 200mm/min, 250mm/min, 300 mm/min).
In the following, an embodiment is listed, and a 3D printing method for a high fiber content continuous fiber reinforced composite material according to the present invention is adopted, in this embodiment, 1K continuous carbon fiber is used as a raw material of the reinforcing fiber for 3D printing, and nylon is used as a raw material of the matrix resin for 3D printing. The 3D printed standard tensile bars (see fig. 1) of this example are as follows:
step 1: according to the current traditional 3D printing path planning technology, modeling software is utilized to model and then layering is carried out through slicing software according to the size requirement of a spline, jump points are processed, finite element analysis is combined, and a continuous fiber reinforced composite material 3D printing traditional path without break points, high quality, high efficiency and low defects is planned. The printing parameters are set as follows by combining the material properties 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 a matrix resin wire is 1.75mm, the matrix resin extrusion multiplying power is 100%, the scanning interval is 1mm, the hot bed temperature is 50 ℃, and the matrix resin is filled by adopting a Chinese character 'Hui'.
Step 2: and (3) adjusting the traditional path in the step (1), positioning the initial printing point of the next layer after the first layer is printed, manually modifying the G code to enable the printing head to move forward by 0.5mm (half scanning interval), modifying the height parameter of the printing layer, reducing by 50%, setting to be 0.2mm, and utilizing computer simulation to ensure that the layer of fibers are laid at the bonding position of the fiber of the last layer and the matrix resin of the fibers.
Step 3: after the second layer is printed, the initial printing point of the next layer is positioned, the G code is manually modified to enable the printing head to move negatively by 0.5mm (half scanning interval), the height of the printing layer is kept to be 0.2mm, and the fiber of the next layer is paved at the bonding position of the fiber of the last layer and the matrix resin of the fiber by utilizing computer simulation.
Step 4: repeating the steps 2 and 3 until the printing height is designated, generating an optimized path code, and leading the optimized path code into an instrument to finish 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 bars.
The present comparative example basically repeats the printing process in the above-described embodiment, except that the conventional 3D printing path (see fig. 3) is obtained only by using step 1, and the optimization is not performed by steps 2 to 4 any more, resulting in a standard stretch spline for conventional path printing.
As can be seen by comparing fig. 2 and 3, for the same component (e.g., standard tensile bars as shown in fig. 1), the bar fiber content produced using the offset compaction strategy proposed by the present invention is significantly higher (67% theoretical improvement) than that produced by the conventional route. And along 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 properties of the component.
The invention has been described in detail in connection with the specific embodiments and exemplary examples thereof, but such description is not to be construed as limiting the invention. It will be understood by those skilled in the art 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, and these fall within the scope of the present invention. The scope of the invention is defined by the appended claims.
Claims (8)
1. A method for 3D printing of a high fiber content continuous fiber reinforced composite material, comprising the steps of:
1) Modeling by modeling software according to the component size requirement, layering by slicing software, processing jump points and combining finite element analysis to plan a 3D printing path of the continuous fiber reinforced composite material without break points;
2) Adjusting the initial positions of the new printing layer and the upper printing layer by combining the component size requirement and the 3D printing path, and laying the fibers of the lower printing layer at the bonding position of the matrix resin of the upper layer by misplacing the adjacent positive and negative half scanning intervals;
3) Setting the printing layer height according to the properties of the fibers and the matrix resin, setting the printing layer height to be 5% -70% of the original layer height, pressing the continuous fibers of the next layer into the matrix resin between the fibers of the previous layer, and carrying out dislocation compaction;
4) Repeating the steps 2) and 3), and optimizing the 3D printing path layer by layer to obtain a new 3D printing path;
5) According to the characteristics of continuous fibers and matrix resin, the temperature of a hot bed, the printing speed and the temperature of a printing head are set, the printing scanning interval, the printing layer height and the spinning speed are set by combining the diameter of the printing head and the width of a fiber bundle, the G code required by a printing instrument is generated by combining a new 3D printing path, the printing process is simulated on a computer, and after the simulation is finished, the continuous fiber reinforced composite material is 3D printed.
2. The method of claim 1, wherein the print layer height is set to 20% -50% of the original layer height.
3. 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, and polyester fibers.
4. The method of claim 1, wherein the matrix resin is one or more of nylon, ABS resin, polylactic acid, polyamide, polyphenylene oxide, polyetheretherketone resin, or one or more of epoxy resin, bismaleimide resin, cyanate ester.
5. The method of claim 1, wherein the printhead temperature is set above a glass transition temperature of the matrix resin and below a decomposition temperature of the matrix resin.
6. The method of claim 5, wherein the printhead temperature is 200-430 ℃.
7. The method of claim 1, wherein the printing speed is 30-300 mm/min.
8. A high fiber content continuous fiber reinforced composite material, characterized in that it is obtained by 3D printing by the method of any one of claims 1 to 7.
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