CN114434824A - Forming method of integral special-shaped composite rib - Google Patents
Forming method of integral special-shaped composite rib Download PDFInfo
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- CN114434824A CN114434824A CN202111600736.9A CN202111600736A CN114434824A CN 114434824 A CN114434824 A CN 114434824A CN 202111600736 A CN202111600736 A CN 202111600736A CN 114434824 A CN114434824 A CN 114434824A
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- 239000002131 composite material Substances 0.000 title claims abstract description 93
- 238000000034 method Methods 0.000 title claims abstract description 56
- 238000004519 manufacturing process Methods 0.000 claims abstract description 35
- 238000003825 pressing Methods 0.000 claims abstract description 33
- 238000000465 moulding Methods 0.000 claims abstract description 15
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 42
- 239000004917 carbon fiber Substances 0.000 claims description 42
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 42
- 239000004744 fabric Substances 0.000 claims description 24
- 241001589086 Bellapiscis medius Species 0.000 claims description 18
- 238000005056 compaction Methods 0.000 claims description 12
- 230000007547 defect Effects 0.000 claims description 7
- 239000000853 adhesive Substances 0.000 claims description 6
- 230000001070 adhesive effect Effects 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 6
- 239000003292 glue Substances 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 6
- 230000002093 peripheral effect Effects 0.000 claims description 6
- 238000005086 pumping Methods 0.000 claims description 6
- 238000004026 adhesive bonding Methods 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 230000006835 compression Effects 0.000 claims description 2
- 238000007906 compression Methods 0.000 claims description 2
- 210000001503 joint Anatomy 0.000 abstract description 3
- 230000011218 segmentation Effects 0.000 abstract description 3
- 238000010586 diagram Methods 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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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
- B29C70/345—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 matched moulds
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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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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Abstract
The invention relates to a forming method of an integral special-shaped composite rib, which comprises the following steps: s1, manufacturing a rib uniform pressing plate; s2, paving and pasting prepreg blanks of the upper half die and the lower half die of the rib; s3, manufacturing twill strips; s4, filling twill strips; s5, bag making and can filling curing forming. The integral special-shaped composite rib can be manufactured by one-step molding through the molding method, the existing parts are reduced to one part, the segmentation and butt joint of the parts are avoided, on one hand, the strength of the rib is effectively improved, on the other hand, the original assembly process is also saved, the production period is shortened, the manufacturing cost is reduced, and the inner and outer web plate surfaces of the product are flat and smooth, and the quality is stable and reliable.
Description
Technical Field
The invention belongs to the technical field of aircraft manufacturing, and particularly relates to a forming method of an integral special-shaped composite rib of a civil manned aircraft.
Background
At present, in the production and manufacturing of aeronautical composite material parts, the one-time forming requirement of parts with complex structures and high requirements on the inner and outer surfaces and assembly precision of products is difficult to meet. Most of the parts are formed by segmenting or parting the dies and then are combined by subsequent processes such as gluing, riveting and the like, so that a large number of tools and dies are increased, the production efficiency is influenced, and the cost is increased.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide the method for molding the integral special-shaped composite rib, which can mold and manufacture the integral special-shaped composite rib at one time, improve the strength of the rib, simplify the working procedures, shorten the production period, reduce the manufacturing cost, enable the inner and outer web surfaces of the product to be flat and smooth and ensure stable and reliable quality.
In order to solve the problems, the technical scheme adopted by the invention is as follows:
the invention provides a method for forming an integral special-shaped composite rib, which comprises the following steps:
s1, manufacturing a rib uniform pressing plate: firstly, paving and pasting a high-temperature-resistant rubber pad on a uniform pressing plate tool, then paving and pasting a high-temperature-resistant composite material prepreg on a large web surface and a small web surface of the uniform pressing plate tool, paving and pasting the high-temperature-resistant composite material prepreg on an R-angle arc of the web surface, not paving and pasting the high-temperature-resistant composite material prepreg on the R-angle arc, paving and pasting the high-temperature-resistant rubber pad on the R-angle arc, making a bag, putting the bag into a furnace, curing and molding, and demolding to obtain a rib uniform pressing plate;
s2, paving and pasting prepreg blanks of the upper half die and the lower half die of the rib: respectively paving prepreg blanks of upper and lower half dies of the rib on an upper forming die and a lower forming die of the rib, then respectively and sequentially paving peelable cloth with adhesive and carbon fiber prepreg on the upper die and the lower die of the rib, avoiding the defects of wrinkling, stacking and the like of the prepreg at the R corners or the curved surfaces of the upper die and the lower die of the rib, and finally closing the upper die and the lower die of the rib;
s3, making twill strips: according to the double-arc filling areas of the inner ribs of the upper die and the lower die after the die assembly of S2, adopting carbon fiber unidirectional tape prepreg to manufacture twister strips with the shape and the size matched on a twister strip forming die;
s4, filling twill strips: firstly, filling twirling strips into double-arc filling areas of matched ribs in shape and size one by one, and then paving carbon fiber fabric prepreg and adhesive strippable cloth on a matched rib tooling;
s5, bag making and tank filling curing forming: and (3) firstly, making a bag from the rib obtained by S4 paving, then placing the uniform pressing plate obtained by S1, knocking, then placing the rib into an autoclave for curing, and discharging the rib out of the autoclave to obtain the integral special-shaped composite rib.
In the above molding method of the integral special-shaped composite rib, step S3 specifically includes: the method comprises the steps of cutting carbon fiber unidirectional tape prepreg into long strips with the width of about 40mm according to the outline and the perimeter of a rib, cutting the long strips into thin filaments with the width of about 2-3 mm, sequentially filling the carbon fiber unidirectional tape prepreg thin filaments into a twill strip forming tool, compacting the carbon fiber unidirectional tape prepreg thin filaments by using a compression bar during filling, wherein the filled carbon fiber unidirectional tape prepreg thin filaments are 0.5-1 mm higher than the plane of a mold, mounting a pressing plate on the twill strip forming tool filled with the carbon fiber unidirectional tape prepreg thin filaments, screwing the pressing plate with screws for compaction, finally placing the twill strip forming tool into a 55-65-degree drying room for heating and pre-compacting for 2 hours, and obtaining the twill strip with the shape and the size consistent with the double-arc filling area of the rib after mold closing after heating and compacting.
The carbon fiber unidirectional tape prepreg adopted in the step S3 for manufacturing the twill and the carbon fiber prepreg adopted in the step S2 for laying the ribs are both carbon fiber fabric materials.
In the above molding method of the integral special-shaped composite rib, step S1 specifically includes: firstly, paving and pasting a whole layer of high-temperature-resistant rubber pad on a uniform pressure plate tool, then paving and pasting two layers of high-temperature-resistant composite prepreg on two large web plates, paving and pasting the two layers of high-temperature-resistant composite prepreg on an R-angle arc of the web plate surface, not paving and pasting the high-temperature-resistant composite prepreg on the R-angle arc, wherein the paved and pasted 2 nd layer of high-temperature-resistant composite prepreg is smaller than the 1 st layer of high-temperature-resistant composite prepreg, and the distance between the peripheral edge of the 1 st layer of high-temperature-resistant composite prepreg and the peripheral edge of the 2 nd layer of high-temperature-resistant composite prepreg is 2 mm; then paving and pasting four layers of high-temperature-resistant composite prepreg on the small web surface, paving and pasting the four layers of high-temperature-resistant composite prepreg on an R-angle arc of the web surface, not paving and pasting the high-temperature-resistant composite prepreg on the R-angle arc, increasing the size of the paved and pasted four layers of high-temperature-resistant composite prepreg layer by layer from bottom to top, and keeping the distance between the peripheral edges of two adjacent layers of high-temperature-resistant composite prepreg at 1 mm; then paving and pasting a whole layer of high-temperature-resistant rubber pad to cover all the surfaces, and paving and pasting two layers of high-temperature-resistant rubber pads in the R-angle area, wherein the two layers of high-temperature-resistant rubber pads exceed the R-angle circular arc; finally, the bag is made, the curing and the forming are carried out in a furnace, and the uniform pressing plate of the rib can be obtained after the demoulding.
In the above molding method of the integral special-shaped composite rib, step S4 specifically includes: firstly, taking out the manufactured twill from the twill tool, filling the twill into a double-arc filling area of a closed rib according to the shape and size of the twill, and hammering the twill by using a rubber hammer so that the twill is more fully filled into the filling area; sequentially paving three layers of carbon fiber fabric prepreg on a tool of the rib after die assembly, and performing vacuum pumping and air cooling compaction once after paving and pasting a whole layer of carbon fiber fabric prepreg, wherein the compaction time is that the vacuum degree is more than or equal to 0.08MPa, and the time is at least 15 min; and finally, paving a layer of peelable cloth with glue to complete all paving work of the ribs, wherein the whole paving process needs to be operated in a controllable environment with the temperature of 18-26 ℃ and the humidity of less than 65%.
In the above molding method of the integral special-shaped composite rib, step S2 specifically includes: laying prepreg blanks of an upper half die and a lower half die of the rib on an upper forming die and a lower forming die of the rib respectively, and then laying a layer of peelable cloth with glue on the upper forming die and the lower forming die of the rib respectively, so that the formed parts can be subjected to work such as co-curing, gluing and the like; sequentially paving eight layers of carbon fiber prepreg on the rib upper and lower forming dies respectively, and performing vacuum pumping and air cooling compaction once after the whole layer of carbon fiber prepreg is paved, wherein the compaction time is that the vacuum degree is more than or equal to 0.08Mpa, and the time is at least 15min, so that the defects of wrinkling, stacking and the like of the carbon fiber prepreg at the R corner or the curved surface of the die are avoided in the paving process; and finally, closing the upper and lower forming dies of the rib, and positioning and locking the bolt through the positioning hole and the positioning pin.
In the above molding method of the integral special-shaped composite rib, step S5 specifically includes: firstly, making bags from the ribs obtained after S4 paving and pasting, and placing the uniform pressing plate obtained in S1, knocking by using a rubber hammer to enable each surface of the uniform pressing plate to be tightly attached to each surface of a rib prepreg blank, ensuring uniform stress of the rib prepreg blank during curing, and ensuring the quality of a product formed by the ribs; then after bag making is finished, carrying out vacuum leakage inspection, wherein when vacuum pumping is carried out, the vacuum degree of the solid laminated piece is not lower than 0.08Mpa, and the reading reduction of a vacuum meter within 5min should not exceed 6.77 Kpa; and then, putting the rib into an autoclave for curing, cooling and taking out of the autoclave after curing to obtain the curing molding of the integral special-shaped composite rib.
Preferably, in order to further ensure the quality of the integrally-shaped special-shaped composite rib obtained by curing, before curing, the rib part needs to be subjected to vacuum degree detection again, the vacuum degree is not lower than 0.08MPa, and the reading reduction of a vacuum meter is not more than 6.77kpa/5 min.
Compared with the prior art, the invention has the beneficial effects that:
by adopting the forming method of the integral special-shaped composite rib, the integral special-shaped composite rib can be formed and manufactured at one time, a plurality of existing parts are reduced to one part, the segmentation and butt joint of the parts are avoided, on one hand, the strength of the rib is effectively improved, on the other hand, the original assembly process is saved, the production period is shortened, the manufacturing cost is reduced, and the inner and outer web plate surfaces of the product are flat and smooth, and the quality is stable and reliable.
Drawings
FIG. 1 is a schematic flow diagram of a method of forming a unitary profiled composite rib according to the present invention;
FIG. 2 is a diagram of a rib equalizer plate obtained in an embodiment of the method of forming a one-piece profiled composite rib of the present invention;
FIG. 3 is a schematic view of a rib mold-wise laying of an embodiment of the method of forming an integral profiled composite rib according to the present invention;
FIG. 4 is a schematic view of an embodiment of a method of forming an integral profiled composite rib according to the present invention after the rib is laid and fitted;
FIG. 5 is a schematic diagram of rib twister strip production in an embodiment of the method for forming an integral special-shaped composite rib according to the invention, wherein 5a is a schematic diagram of a rib twister strip forming tool, and 5b is a schematic diagram of a unidirectional tape prepreg filament filled in the twister strip forming tool;
FIG. 6 is a view showing the rib after being clamped and the twister strip is filled to a clamping seam in the embodiment of the method for molding the integral special-shaped composite rib;
FIG. 7 is another view of the rib after clamping and filling the twist strips into the clamping seam in the embodiment of the method for forming the integral special-shaped composite rib of the invention;
FIG. 8 is a view of a one-piece profiled composite rib produced in an embodiment of the method of forming a one-piece profiled composite rib in accordance with the present invention;
FIG. 9 is another view of a one-piece profiled composite rib made in an embodiment of the method of forming the one-piece profiled composite rib of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As shown in FIG. 1, the invention provides a method for forming an integral special-shaped composite rib, which comprises the following steps:
s1, manufacturing a rib uniform pressing plate: firstly, paving and pasting a high-temperature-resistant rubber pad on a uniform pressing plate tool, then paving and pasting a high-temperature-resistant composite material prepreg on a large web surface and a small web surface of the uniform pressing plate tool, paving and pasting the high-temperature-resistant composite material prepreg on an R-angle arc of the web surface, not paving and pasting the high-temperature-resistant composite material prepreg on the R-angle arc, paving and pasting the high-temperature-resistant rubber pad on the R-angle arc, making a bag, putting the bag into a furnace, curing and molding, and demolding to obtain a rib uniform pressing plate;
s2, paving and pasting prepreg blanks of the upper half die and the lower half die of the rib: respectively paving prepreg blanks of upper and lower half dies of the rib on an upper forming die and a lower forming die of the rib, then respectively and sequentially paving peelable cloth with adhesive and carbon fiber prepreg on the upper die and the lower die of the rib, avoiding the defects of wrinkling, stacking and the like of the prepreg at the R corners or the curved surfaces of the upper die and the lower die of the rib, and finally closing the upper die and the lower die of the rib;
s3, making twill strips: according to the double-arc filling areas of the inner ribs of the upper die and the lower die after the die assembly of S2, adopting carbon fiber unidirectional tape prepreg to manufacture twister strips with the shape and the size matched on a twister strip forming die;
s4, filling twill strips: firstly, filling twirling strips into double-arc filling areas of matched ribs in shape and size one by one, and then paving carbon fiber fabric prepreg and adhesive strippable cloth on a matched rib tooling;
s5, bag making and tank filling curing forming: and (3) firstly, making a bag from the rib obtained by S4 paving, then placing the uniform pressing plate obtained by S1, knocking, then placing the rib into an autoclave for curing, and taking out the rib from the autoclave to obtain the integral special-shaped composite rib.
The forming method of the integral special-shaped composite rib can be used for forming and manufacturing the integral special-shaped composite rib at one time, reduces a plurality of existing parts to one part, avoids the segmentation and butt joint of the parts, effectively improves the strength of the rib on one hand, saves the original assembly process on the other hand, shortens the production period, reduces the manufacturing cost, and can ensure that the inner and outer web plate surfaces of the product are flat and smooth and the quality is stable and reliable.
The method for forming the rib of the integral special-shaped composite material is further explained by the following embodiments.
The embodiment is as follows:
this example is a method for forming a rib of an integrated profiled composite material according to the invention for manufacturing a rib used in an AG300, AG600 aircraft full composite spoiler. The forming method comprises the following steps of:
firstly, manufacturing a uniform pressure plate. Firstly, paving and pasting 1 whole layer of high-temperature-resistant rubber pad on a uniform pressure plate tool, then paving and pasting 2 layers of high-temperature-resistant composite prepreg on two large web plates, paving and pasting 2 layers of high-temperature-resistant composite prepreg at an R-angle arc, wherein the 2 nd layer of high-temperature-resistant composite prepreg is required to be 2mm smaller than each of four sides of the 1 st layer of high-temperature-resistant composite prepreg, paving and pasting 4 layers of high-temperature-resistant composite prepreg on a small web plate surface, paving and pasting 4 layers of high-temperature-resistant composite prepreg at the R-angle arc, and the next layer of high-temperature-resistant composite prepreg is required to be 1mm smaller than each side of the previous layer of high-temperature-resistant composite prepreg, gradually decreasing layer by layer, and not paving and pasting the high-temperature-resistant composite prepreg in R-angle regions (R-angle arcs) on two sides; then paving a whole layer of rubber pad to cover all surfaces, additionally paving 2 layers of high-temperature-resistant rubber pads in the two R-angle areas, wherein the 2 layers of high-temperature-resistant rubber pads exceed the R-angle circular arc; finally, the rib uniform-pressing plate (as shown in figure 2) can be obtained after the bag is made, the bag is put into a furnace for curing and forming and the mold is released, the uniform-pressing plate can be repeatedly used for many times, the rib part is manufactured before the first-time rib part forming, and the subsequent production does not need to be manufactured again.
And secondly, paving and sticking prepreg blanks of the upper half die and the lower half die of the rib. The prepreg blanks of the upper half die and the lower half die of the rib are respectively paved on the upper forming die and the lower forming die of the rib. According to the requirements of related documents, 1 layer of peelable cloth with glue is firstly paved on an upper die and a lower die of a rib respectively, so that the formed parts can be subjected to co-curing, gluing and other work conveniently; then according to related process files, 8 layers of carbon fiber prepreg are sequentially paved on an upper forming die and a lower forming die of the rib respectively, and when 1 whole layer of prepreg is paved, vacuumizing and cold compaction are needed for 1 time, the compaction time is not less than 0.08Mpa, the time is at least 15min, in the paving process, the defects of wrinkling, stacking and the like of the prepreg at the R corner or the curved surface of the die are avoided, meanwhile, the prepreg can be tightly compacted at the R corner and between layers, the gas mixed between the prepreg layers is completely discharged, and the product quality is ensured; and finally, after 8 layers of carbon fiber prepregs are laid on the upper and lower forming dies of the rib, closing the upper and lower forming dies, positioning the upper and lower forming dies by the positioning holes and the positioning pins, and locking by bolts (as shown in fig. 3 and 4).
And thirdly, manufacturing twigs. And (3) manufacturing the twiddle on a corresponding twiddle forming die by using a carbon fiber unidirectional tape prepreg, wherein the material performance of the carbon fiber unidirectional tape prepreg is consistent with that of a carbon fiber fabric material used for paving the ribs. When the twister strip is manufactured, firstly cutting the prepreg of the unidirectional tape into long strips with the width of about 40mm according to the shape perimeter of the ribs, then cutting the prepreg long strips of the unidirectional tape into thin wires with the width of about 2-3 mm, and sequentially filling the thin wires of the prepreg of the unidirectional tape into a twister strip forming tool, wherein during filling, the thin wires of the prepreg of the unidirectional tape need to be tightly pressed by a pressing rod, and the filled prepreg wires of the unidirectional tape need to be 0.5-1 mm higher than the plane of a mould; and then, after filling, installing an upper pressing plate, screwing down and compacting by screws, then putting the tool into a drying room with the temperature of 55-65 ℃ for heating and pre-compacting for 2 hours, and after heating and compacting, not only enabling the shape (shape and size) of the twister strip to be consistent with the shape of the double-arc filling area of the rib after die assembly, but also ensuring that the twister strip is formed more compactly and improving the quality of the twister strip (as shown in figure 5).
And fourthly, filling twill strips. Taking out the manufactured twill from the twill tool, and filling the twill into a double-arc filling area of a matched die rib according to the shape of the twill; then hammering the twister strip by using a rubber hammer to enable the twister strip to be more fully filled into the filling area; sequentially paving and pasting 3 layers of carbon fiber fabric prepreg on the assembled rib tool, wherein vacuumizing and cold compacting are needed for 1 time when 1 whole layer of carbon fiber fabric prepreg is paved and pasted, the compacting time is real, the vacuum degree is not less than 0.08MPa, and the time is at least 15 min; and finally, paving 1 layer of peelable cloth with glue to complete all paving work of the ribs (as shown in figures 6 and 7), wherein the whole paving process needs to be operated in a controllable environment with the temperature of 18-26 ℃ and the humidity of less than 65 percent, so that the material can be effectively prevented from absorbing excessive moisture in the air, the product quality and the mechanical property can be ensured, the material can be ensured to be in a state which is most beneficial to operation by controlling the temperature in the range, and the product quality and the working efficiency can be improved.
Fifthly, making bags, putting into a tank, curing and forming. After the ribs are paved and attached, firstly, bag making is carried out according to a bag making process, a uniform pressing plate is placed, and the uniform pressing plate can be knocked by using a rubber hammer at the moment, so that each surface of the uniform pressing plate is tightly attached to each surface of a rib prepreg blank, the rib prepreg blank is uniformly stressed during curing, and the product quality after rib forming is ensured; then after the bag making is finished, carrying out vacuum leakage inspection: when the vacuum is pumped, the vacuum degree of the solid laminated piece is not lower than 0.08Mpa, and the reading reduction of a vacuum meter within 5min should not exceed 6.77 Kpa; secondly, the ribs are placed into an autoclave for curing, the curing of the composite material ribs is carried out according to relevant curing process data, before the curing, the vacuum degree of the rib workpiece needs to be detected again, the vacuum degree is not lower than 0.08MPa, and the reading of a vacuum meter is reduced by 6.77kpa/5 min; and finally, after solidification, when the rib tooling is cooled to room temperature, taking out the rib tooling from the tank, and finishing the solidification molding of the integral special-shaped composite material rib (figures 8 and 9).
The forming method of the integral special-shaped composite rib adopts a more optimal layering process method, a uniform pressure plate forming method (uniform pressure plate manufacturing) and a curing forming process method, so that the forming production period of the integral special-shaped composite rib is short, the manufacturing cost is low, the product quality is stable and reliable, good economic benefits are achieved, and meanwhile, corresponding technical reserves are provided for the production and the manufacture of domestic related special-shaped composite parts.
The above embodiments are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited thereby, and any insubstantial changes and substitutions made by those skilled in the art based on the present invention are within the protection scope of the present invention.
Claims (7)
1. A method of forming a unitary profiled composite rib, comprising:
s1, manufacturing a rib uniform pressing plate: firstly, paving and pasting a high-temperature-resistant rubber pad on a uniform pressing plate tool, then paving and pasting a high-temperature-resistant composite material prepreg on a large web surface and a small web surface of the uniform pressing plate tool, paving and pasting the high-temperature-resistant composite material prepreg on an R-angle arc of the web surface, not paving and pasting the high-temperature-resistant composite material prepreg on the R-angle arc, paving and pasting the high-temperature-resistant rubber pad on the R-angle arc, making a bag, putting the bag into a furnace, curing and molding, and demolding to obtain a rib uniform pressing plate;
s2, paving and pasting prepreg blanks of the upper half die and the lower half die of the rib: respectively paving prepreg blanks of upper and lower half dies of the rib on an upper forming die and a lower forming die of the rib, then respectively and sequentially paving peelable cloth with adhesive and carbon fiber prepreg on the upper die and the lower die of the rib, avoiding the defects of wrinkling, stacking and the like of the prepreg at the R corners or the curved surfaces of the upper die and the lower die of the rib, and finally closing the upper die and the lower die of the rib;
s3, making twill strips: according to the double-arc filling areas of the inner ribs of the upper die and the lower die after the die assembly of S2, adopting carbon fiber unidirectional tape prepreg to manufacture twister strips with the shape and the size matched on a twister strip forming die;
s4, filling twill strips: firstly, filling twirling strips into double-arc filling areas of matched ribs in shape and size one by one, and then paving carbon fiber fabric prepreg and adhesive strippable cloth on a matched rib tooling;
s5, bag making and tank filling curing forming: and (3) firstly, making a bag from the rib obtained by S4 paving, then placing the uniform pressing plate obtained by S1, knocking, then placing the rib into an autoclave for curing, and taking out the rib from the autoclave to obtain the integral special-shaped composite rib.
2. The method for forming an integral profiled composite rib as claimed in claim 1, wherein the step S3 is specifically: the method comprises the steps of cutting carbon fiber unidirectional tape prepreg into long strips with the width of about 40mm according to the outline and the perimeter of a rib, cutting the long strips into thin filaments with the width of about 2-3 mm, sequentially filling the carbon fiber unidirectional tape prepreg thin filaments into a twill strip forming tool, compacting the carbon fiber unidirectional tape prepreg thin filaments by using a compression bar during filling, wherein the filled carbon fiber unidirectional tape prepreg thin filaments are 0.5-1 mm higher than the plane of a mold, mounting a pressing plate on the twill strip forming tool filled with the carbon fiber unidirectional tape prepreg thin filaments, screwing the pressing plate with screws for compaction, finally placing the twill strip forming tool into a 55-65-degree drying room for heating and pre-compacting for 2 hours, and obtaining the twill strip with the shape and the size consistent with the double-arc filling area of the rib after mold closing after heating and compacting.
3. The method for forming an integral special-shaped composite rib according to claim 2, wherein the carbon fiber unidirectional tape prepreg adopted for manufacturing the twister strip in the step S3 and the carbon fiber prepreg adopted for paving the rib in the step S2 are both carbon fiber fabric materials.
4. The method for forming an integral profiled composite rib as claimed in claim 1, 2 or 3, wherein the step S1 is specifically: firstly, paving and pasting a whole layer of high-temperature-resistant rubber pad on a uniform pressure plate tool, then paving and pasting two layers of high-temperature-resistant composite prepreg on two large web plates, paving and pasting the two layers of high-temperature-resistant composite prepreg on an R-angle arc of the web plate surface, not paving and pasting the high-temperature-resistant composite prepreg on the R-angle arc, wherein the paved and pasted 2 nd layer of high-temperature-resistant composite prepreg is smaller than the 1 st layer of high-temperature-resistant composite prepreg, and the distance between the peripheral edge of the 1 st layer of high-temperature-resistant composite prepreg and the peripheral edge of the 2 nd layer of high-temperature-resistant composite prepreg is 2 mm; then paving and pasting four layers of high-temperature-resistant composite prepreg on the small web surface, paving and pasting the four layers of high-temperature-resistant composite prepreg on an R-angle arc of the web surface, not paving and pasting the high-temperature-resistant composite prepreg on the R-angle arc, increasing the size of the paved and pasted four layers of high-temperature-resistant composite prepreg layer by layer from bottom to top, and keeping the distance between the peripheral edges of two adjacent layers of high-temperature-resistant composite prepreg at 1 mm; then paving and pasting a whole layer of high-temperature-resistant rubber pad to cover all the surfaces, and paving and pasting two layers of high-temperature-resistant rubber pads in the R-angle area, wherein the two layers of high-temperature-resistant rubber pads exceed the R-angle circular arc; finally, the bag is made, the curing and the forming are carried out in a furnace, and the uniform pressing plate of the rib can be obtained after the demoulding.
5. The method for forming an integral profiled composite rib as claimed in claim 1, 2 or 3, wherein the step S4 is specifically: firstly, taking out the manufactured twill from the twill tool, filling the twill into a double-arc filling area of a closed rib according to the shape and size of the twill, and hammering the twill by using a rubber hammer so that the twill is more fully filled into the filling area; sequentially paving three layers of carbon fiber fabric prepreg on a tool of the rib after die assembly, and performing vacuum pumping and air cooling compaction once after paving and pasting a whole layer of carbon fiber fabric prepreg, wherein the compaction time is that the vacuum degree is more than or equal to 0.08MPa, and the time is at least 15 min; and finally, paving a layer of peelable cloth with glue to complete all paving work of the ribs, wherein the whole paving process needs to be operated in a controllable environment with the temperature of 18-26 ℃ and the humidity of less than 65%.
6. The method for forming an integral profiled composite rib as claimed in claim 1, 2 or 3, wherein the step S2 is specifically: laying prepreg blanks of an upper half die and a lower half die of the rib on an upper forming die and a lower forming die of the rib respectively, and then laying a layer of peelable cloth with glue on the upper forming die and the lower forming die of the rib respectively, so that the formed parts can be subjected to work such as co-curing, gluing and the like; sequentially paving eight layers of carbon fiber prepreg on the rib upper and lower forming dies respectively, and performing vacuum pumping and air cooling compaction once after the whole layer of carbon fiber prepreg is paved, wherein the compaction time is that the vacuum degree is more than or equal to 0.08Mpa, and the time is at least 15min, so that the defects of wrinkling, stacking and the like of the carbon fiber prepreg at the R corner or the curved surface of the die are avoided in the paving process; and finally, closing the upper and lower forming dies of the rib, and positioning and locking the bolt through the positioning hole and the positioning pin.
7. The method for forming an integral profiled composite rib as claimed in claim 1, 2 or 3, wherein the step S5 is specifically: firstly, making bags from the ribs obtained after S4 paving and pasting, and when placing the uniform pressing plate obtained in S1, knocking by using a rubber hammer to enable each surface of the uniform pressing plate to be tightly attached to each surface of a rib prepreg blank, so that the rib prepreg blank is uniformly stressed during curing, and the quality of a product formed by the ribs is ensured; then after bag making is finished, carrying out vacuum leakage inspection, wherein when vacuum pumping is carried out, the vacuum degree of the solid laminated piece is not lower than 0.08Mpa, and the reading reduction of a vacuum meter within 5min should not exceed 6.77 Kpa; and then, putting the rib into an autoclave for curing, cooling and taking out of the autoclave after curing to obtain the curing molding of the integral special-shaped composite rib.
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