CN114792059A - Simulation system and simulation method for composite material autoclave process calculated by freezing part - Google Patents
Simulation system and simulation method for composite material autoclave process calculated by freezing part Download PDFInfo
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Abstract
The invention relates to a simulation system and a simulation method for a composite material autoclave process with freezing part calculation, and belongs to the technical field of composite material autoclave processes. The redundant calculation in the simulation of the autoclave process can be greatly reduced through the calculation of the flow and the temperature related to the freezing part of the fluid, and the temperature field, the pressure field and the curing degree field of the composite material in the autoclave process can be obtained efficiently.
Description
Technical Field
The invention relates to the technical field of composite material autoclave processes, in particular to a simulation system and a simulation method for a composite material autoclave process with freezing part calculation.
Background
Since the mid-60 s of the last century, advanced resin-based composite materials have been widely used in high-tech fields such as aviation, aerospace, navigation and the like and civil industry due to their unique characteristics, and have become one of the most important and indispensable materials in modern industrial fields. The autoclave process is the most widely applied and representative process method for preparing advanced composite materials, and has the characteristics of high uniformity of pressure in the autoclave, high uniformity of temperature in the autoclave, stable and reliable molding process and wide application range, and more than 80 percent of aircraft composite material structures are manufactured by the autoclave process.
Meanwhile, the autoclave hardware system is huge, the structure is complex, the autoclave belongs to special equipment, the investment cost is high, and a large amount of high-value process auxiliary materials and a large amount of energy are consumed in each process, so the autoclave process cost is high. In the autoclave process, a composite material and a composite material member are simultaneously molded under the action of high-temperature and high-pressure gas in an autoclave, the composite material relates to complex interaction of heat and pressure in a multi-phase material system (namely a tool, an auxiliary material, a fiber and resin composite system and the like) in the process, and the tool, process parameters and the like are always required to be redesigned and optimized after the material type, the form of the composite material member and the like are changed. In the traditional 'trial and error method' research and development mode, repeated tests are needed from a sample to a scaled part to a test part, the research cost is high, the controllability of the manufacturing quality of the composite material is poor, the qualified rate of the part is low, and the research efficiency and the application of the composite material are restricted.
With the rapid development of semiconductor integrated circuit technology in the 21 st century, the operational capability of microcomputers has been improved continuously, and simulation and optimization of autoclave process by computer simulation method has become an important part of the advanced composite material manufacturing process. On the basis of the research on the physicochemical action mechanism related to the autoclave process, the numerical analysis method established based on the finite difference method, the finite volume method or the finite element method can effectively guide the design and optimization of the process and the tool, and provides powerful technical support for the transition of the advanced composite material development mode from the traditional cordwood verification to the digital manufacturing mode.
However, when the composite autoclave process is simulated by a numerical analysis method represented by a finite element method, the autoclave is generally 10 in size 0 ～10 1 m is of the order of magnitude, and the thickness of the composite article is typically 10 a -4 ～10 -3 m orders of magnitude, the number of grids occupied by the autoclave flow field is huge, on one hand, high requirements are put on grid division, and on the other hand, the simulation efficiency is seriously reduced due to the huge grid quantity. According to the working characteristics of the autoclave, most of the calculation of fluid flow and fluid temperature related to high-temperature and high-pressure gas (flow field) in the autoclave in the technological process is redundant, so that part of simulation work has to simplify the whole physical process due to the fact of scientific research and engineering, and the influence of the flow of the working gas of the autoclave which has great influence on the temperature/pressure boundary of a workpiece is ignored, so that the simulation is completed within limited time, but even if the time is allowed, the calculation of the gas flow can generate a large amount of low-value data, thereby not only wasting storage space, but also reducing the efficiency of extracting effective data from the calculation result.
Therefore, a high-efficiency simulation system and a high-efficiency simulation method for an autoclave process, which can reduce redundant calculation without simplifying the physical process, are needed.
Disclosure of Invention
The invention aims to provide a composite material autoclave process simulation system and a composite material autoclave process simulation method for freezing part calculation, which can reduce redundant calculation on the premise of not simplifying the physical process so as to improve the simulation efficiency.
In order to achieve the purpose, the invention provides the following scheme:
a simulation method for freezing part of a calculated composite autoclave process, the simulation method comprising:
carrying out three-dimensional modeling according to the autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, and carrying out mesh generation treatment on the obtained three-dimensional model to obtain an autoclave process model;
taking the autoclave process parameters as the input of the autoclave process model to obtain initial fluid process parameters; the fluid process parameters include a distribution of velocity, pressure, density, viscosity, and temperature in time and space;
judging whether the fluid process parameter is in a frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter;
if the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as a fluid process parameter to be output;
if the fluid process parameters need to be updated and are not in the frozen state, updating the fluid process parameters to obtain fluid process parameters to be output;
if the fluid process parameter is not in the frozen state and does not need to be updated, interpolating between the fluid process parameter which is before the fluid process parameter and in the frozen state and the fluid process parameter which is after the fluid process parameter and in the frozen state to obtain a fluid process parameter to be output;
calculating a solid process parameter according to the process parameter of the fluid to be output; the solid process parameters comprise distribution of temperature, pressure and the degree of solidification of the workpiece in time and space;
judging whether the simulation stopping time is reached;
if not, taking the fluid process parameter to be output as the fluid process parameter of the next iteration, and returning to the step of judging whether the fluid process parameter is in the frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter.
A composite autoclave process simulation system with freezing part calculation comprises an interaction and control module, a fluid calculation module and a solid calculation module;
the interaction and control module comprises:
the spatial configuration and mesh generation unit is used for receiving and storing the input autoclave construction parameters, the part construction parameters and the mold construction parameters, performing three-dimensional modeling according to the autoclave construction parameters, the part construction parameters and the mold construction parameters, and performing mesh generation processing on the obtained three-dimensional model to obtain an autoclave process model;
the process parameter setting unit is used for receiving and storing the input autoclave process parameters;
the calculation control core unit is used for taking the autoclave process parameters as the input of the autoclave process model to obtain initial fluid process parameters; judging whether the simulation stop time is reached or not, and controlling the fluid calculation module and the solid calculation module to work by taking the fluid process parameter to be output as the fluid process parameter of the next iteration when the simulation stop time is not reached; the fluid process parameters include distribution of velocity, pressure, density, viscosity and temperature in time and space;
the fluid calculating module is used for judging whether the fluid process parameter is in a frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter; if the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as a fluid process parameter to be output; if the fluid process parameters need to be updated and are not in the frozen state, updating the fluid process parameters to obtain fluid process parameters to be output; if the fluid process parameter is not in the frozen state and does not need to be updated, interpolating between the fluid process parameter which is before the fluid process parameter and in the frozen state and the fluid process parameter which is after the fluid process parameter and in the frozen state to obtain a fluid process parameter to be output;
the solid calculation module is used for calculating solid process parameters according to the process parameters of the fluid to be output; the solid process parameters include the distribution of temperature, pressure and degree of cure of the part in time and space.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention provides a composite material autoclave process simulation system and a simulation method for calculating a freezing part, which can greatly reduce redundant calculation in autoclave process simulation through calculation of flow and temperature related to the freezing part, and efficiently obtain a temperature field, a pressure field and a curing degree field of a composite material in an autoclave process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
Fig. 1 is a flowchart of a simulation method according to embodiment 1 of the present invention;
FIG. 2 is a schematic diagram of a simulation method provided in embodiment 1 of the present invention;
fig. 3 is a system block diagram of a simulation system provided in embodiment 2 of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a simulation system and a simulation method for a composite material autoclave process with freezing part calculation. In the calculation, the simulation system and the simulation method greatly reduce the redundant calculation in the autoclave process simulation through the flow calculation and the temperature calculation of the frozen part fluid, obviously improve the calculation efficiency, and can reduce the redundant calculation on the premise of not simplifying the physical process so as to improve the simulation efficiency.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example 1:
the present embodiment is configured to provide a simulation method for a composite autoclave process by calculating a frozen portion, and is used to simulate rapid simulation of a temperature field and a curing field of a composite material product/product blank in an autoclave process, as shown in fig. 1 and fig. 2, where the simulation method includes:
s1: carrying out three-dimensional modeling according to autoclave construction parameters, part construction parameters and mould construction parameters, and carrying out mesh subdivision treatment on the obtained three-dimensional model to obtain an autoclave process model;
specifically, the autoclave construction parameters include the shape of the autoclave body, the size of the autoclave body, the type and material parameters of the working gas, the flow rate of the working gas, the heating mode and the cooling mode. The parameters of the part construction comprise the shape of the part, the size of the part, the thickness of the part, the layering structure of the preformed body, the type of the material used by the part and the material parameters thereof. The mold construction parameters include the shape of the mold, the size of the mold, the thickness of the mold, the type of material used for the mold, and material parameters thereof.
More specifically, the types of the working gas include air, nitrogen, argon, and the like. The material parameters of the working gas include the density, viscosity, specific heat capacity and thermal conductivity of the material. The types of materials used by the workpiece comprise fiber types, resin types and fabric types, wherein the fiber types comprise glass fibers, carbon fibers, aramid fibers, basalt fibers and the like, the resin types comprise epoxy resins, phenolic resins, cyanate resins, bismaleimide resins and the like, and the fabric types comprise unidirectional fabrics, plain fabrics, twill fabrics, satin fabrics, puncture fabrics, three-dimensional woven fabrics and the like. The material parameters of the material used for the part include the density, specific heat capacity, thermal conductivity, cure exotherm, cure kinetic model and fiber volume fraction of the material. The types of materials used for the mold include metal materials such as iron, steel, aluminum, copper, titanium and the like, and alloys thereof, as well as plastics, wood, composite materials and the like. The material parameters of the material used for the mold include the density, specific heat capacity and thermal conductivity of the material.
S1 may include: and performing three-dimensional modeling on the space occupied by the autoclave working gas, the parts, the die and other process auxiliary materials according to the autoclave construction parameters, the part construction parameters and the die construction parameters, and performing mesh generation treatment on the obtained three-dimensional model of the fluid and solid space to obtain the autoclave process model with nodes and meshes.
S2: taking the autoclave process parameters as the input of the autoclave process model to obtain initial fluid process parameters; the fluid process parameters include a distribution of velocity, pressure, density, viscosity, and temperature in time and space;
specifically, the autoclave process parameters include the variation of curing temperature with time, the variation of curing pressure with time, the variation of vacuum pressure with time, the demolding temperature, and the auxiliary materials and material parameters used in the process. The types of auxiliary materials used by the process comprise vacuum bag films, air-permeable felts, demoulding materials, demoulding agents, release paper, adhesive blocking strips, sealing adhesive tapes, uniform pressing plates and the like. The material parameters of the auxiliary materials used in the process comprise the type, the using mode, the density, the specific heat capacity and the heat conductivity coefficient of the materials.
S3: judging whether the fluid process parameter is in a frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter;
specifically, the fluid state freezing determination parameter includes a maximum time for which the fluid is allowed to be frozen, a maximum temperature change value from the freezing time to the current time, a maximum speed change value from the freezing time to the current time, and a maximum pressure change value from the freezing time to the current time. The fluid status update decision parameters include a maximum time allowed between two fluid calculation updates, a maximum temperature change value from a last fluid update time to a current time, a maximum velocity change value from the last fluid update time to the current time, and a maximum pressure change value from the last fluid update time to the current time.
Based on the fluid state freezing determination parameter and the fluid state updating determination parameter, S3 may include:
when the time from the freezing moment to the current moment exceeds the longest time for allowing the fluid to be frozen, the temperature change value from the freezing moment to the current moment exceeds the maximum temperature change value from the freezing moment to the current moment, the speed change value from the freezing moment to the current moment exceeds the maximum speed change value from the freezing moment to the current moment, or the pressure change value from the freezing moment to the current moment exceeds the maximum pressure change value from the freezing moment to the current moment, the fluid process parameter is not in a freezing state; otherwise, the fluid process parameter is in a frozen state.
When the time from the last fluid updating time to the current time exceeds the longest time between two allowable fluid calculation updates, the temperature change value from the last fluid updating time to the current time exceeds the maximum temperature change value from the last fluid updating time to the current time, the speed change value from the last fluid updating time to the current time exceeds the maximum speed change value from the last fluid updating time to the current time, or the pressure change value from the last fluid updating time to the current time exceeds the maximum pressure change value from the last fluid updating time to the current time, the fluid process parameters need to be updated; otherwise, the fluid process parameters do not need to be updated.
After the judgment results of whether the fluid process parameters are in the frozen state and whether the fluid process parameters need to be updated are obtained, the processing mode is as follows:
(1) if the fluid process parameter is in a frozen state and does not need to be updated, directly taking the fluid process parameter as the fluid process parameter to be output;
(2) if the fluid process parameter needs to be updated and is not in the frozen state, updating the fluid process parameter to obtain a fluid process parameter to be output;
specifically, the updating method comprises the following steps: and calculating to obtain the process parameters of the fluid to be output by using a finite difference method or a finite volume method or a finite element method according to the autoclave construction parameters, the autoclave process model and the autoclave process parameters.
(3) If the fluid process parameter is not in the frozen state and does not need to be updated, interpolating between the fluid process parameter which is in front of the fluid process parameter and in the frozen state and the fluid process parameter which is behind the fluid process parameter and in the frozen state to obtain a fluid process parameter to be output;
it should be noted that, the simulation process in this embodiment is a time-step-by-time-step iteration process, and therefore, before the fluid process parameter means that the calculation time step is before the calculation time step corresponding to the fluid process parameter of this iteration, and after the fluid process parameter means that the calculation time step is after the calculation time step corresponding to the fluid process parameter of this iteration.
S4: calculating a solid process parameter according to the process parameter of the fluid to be output; the solid process parameters comprise distribution of temperature, pressure and the degree of solidification of the workpiece in time and space;
s4 may include: and calculating the parameters of the solid process by using a finite difference method or a finite volume method or a finite element method according to the parameters of the autoclave construction, the autoclave process model, the autoclave process parameters and the process parameters of the fluid to be output.
S5: judging whether the simulation stopping time is reached; if not, taking the fluid process parameter to be output as a fluid process parameter of the next iteration, and returning to the step of judging whether the fluid process parameter is in a frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter.
In this embodiment, a finite difference method, a finite element method, or a finite volume method is used to simulate the curing process of a complex composite material workpiece in the autoclave process, so as to predict the distribution of temperature in time and space, the distribution of pressure in time and space, and the distribution law of curing degree in time and space in the workpiece. Meanwhile, by setting a fluid state freezing judgment parameter and a fluid state updating judgment parameter and calculating the flow and unsteady temperature related to the frozen part of the fluid, the redundant fluid calculation in the autoclave process simulation can be obviously reduced, the calculation time is greatly reduced, and the simulation efficiency is improved.
Example 2:
the present embodiment is configured to provide a simulation system for a composite autoclave process by calculating a frozen portion, and is a digital system for predicting a temperature change and a growth rule of a degree of curing of a composite product/product blank under an influence of a non-uniform product boundary caused by a non-uniform autoclave working gas flow with high efficiency by using a computer. As shown in fig. 3, the simulation system includes an interaction and control module, a fluid calculation module, and a solids calculation module;
the interaction and control module is used for receiving the input autoclave construction parameters, the finished piece construction parameters, the die construction parameters and the autoclave process parameters, controlling the overall calculation process and outputting the process parameters. The process parameters include fluid process parameters and solid process parameters.
Specifically, the interaction and control module may include: the device comprises a calculation control core unit, a space configuration and mesh generation unit, a process parameter setting unit and a process parameter output unit which are respectively connected with the calculation control core unit.
The space configuration and mesh generation unit is used for receiving and storing the inputted autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, carrying out three-dimensional modeling on the space occupied by the autoclave working gas, the workpiece, the mould and other process auxiliary materials according to the autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, carrying out mesh generation treatment on the obtained three-dimensional model of the fluid and the solid space to obtain an autoclave process model with nodes and meshes, and storing the autoclave process model as a data file for the call of the calculation control core unit.
And the process parameter setting unit is used for receiving and storing the input autoclave process parameters for the calculation control core unit to call.
The space configuration and mesh generation unit and the process parameter setting unit of the embodiment receive and store the input parameters for the fluid process parameter updating unit and the solid process parameter updating unit to call, so that the input parameters can be adjusted in real time.
And the calculation control core unit is used for controlling the whole calculation process, including parameter transmission among the fluid calculation module, the solid calculation module and the interaction and control module, and judging and determining whether to end the simulation process. Specifically, the calculation control core unit is used for taking autoclave process parameters as input of an autoclave process model to obtain initial fluid process parameters and transmitting the fluid process parameters to the fluid calculation module; and after the fluid calculation module and/or the solid calculation module finishes one iteration, judging whether the simulation stop time is reached, and when the simulation stop time is not reached, controlling the fluid calculation module and the solid calculation module to continue working by taking the process parameters of the fluid to be output as the process parameters of the fluid of the next iteration. Fluid process parameters include distribution of velocity, pressure, density, viscosity and temperature in time and space.
The technical process parameter output unit is used for outputting the to-be-output fluid process parameters and the solid process parameters of each calculation time step obtained in the simulation process, performing format conversion on the to-be-output fluid process parameters and the solid process parameters, and converting the to-be-output fluid process parameters and the solid process parameters into a format which is easy to read by an operator and/or a format which is easy to store through a computer. The process parameter output unit of the embodiment can output the fluid process parameter and the solid process parameter to other purposes.
The fluid calculation module is used for calculating fluid process parameters. Specifically, the fluid calculation module is used for judging whether the fluid process parameter is in a frozen state and whether the fluid process parameter needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter; if the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as the fluid process parameter to be output; if the fluid process parameters need to be updated and are not in the frozen state, updating the fluid process parameters to obtain the fluid process parameters to be output; if the fluid process parameter is not in the frozen state and does not need to be updated, interpolating between the fluid process parameter which is before the fluid process parameter and is in the frozen state and the fluid process parameter which is after the fluid process parameter and is in the frozen state to obtain the fluid process parameter to be output.
More specifically, the fluid calculating module of the present embodiment includes: the device comprises a fluid process state judgment unit, a fluid process parameter updating unit, a fluid process parameter storage unit and a fluid process parameter processing and output unit. The fluid process state judging unit is connected with the calculation control core unit, the fluid process parameter updating unit and the fluid process parameter storage unit, the fluid process parameter updating unit is connected with the fluid process parameter storage unit, and the fluid process parameter processing and outputting unit is respectively connected with the calculation control core unit, the fluid process parameter updating unit and the fluid process parameter storage unit.
And the fluid process state judgment unit is used for judging whether the fluid process parameters of the current calculation time step are in a frozen state and need to be updated or not according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter, and judging whether the current calculation time step and the previous calculation time step are in the same frozen state or not if the current calculation time step is in the frozen state.
And the fluid process parameter updating unit is used for calling and calculating the process parameters of the fluid to be output in the current calculation time step by using a finite difference method, a finite volume method or a finite element method according to the autoclave construction parameters, the autoclave process model and the autoclave process parameters, and sending the process parameters of the fluid to be output to the fluid process parameter storage unit and the fluid process parameter processing and output unit. The fluid process parameter updating unit of the embodiment is based on the combination of a mathematical computation model and a computer technology, and adopts a finite difference method, a finite volume method or a finite element method to simulate a working gas flow field and a temperature field in a composite material autoclave process, so that the non-uniform velocity and temperature distribution caused by the non-uniform autoclave working gas flow can be obtained without experiments.
And the fluid process parameter storage unit is used for storing the fluid process parameters in the frozen state, and when the fluid process parameter storage unit is called by the fluid process parameter processing and output unit, the specified one or more fluid process parameters in the frozen state are sent to the fluid process parameter processing and output unit.
The fluid process parameter processing and outputting unit is used for processing the fluid process parameters according to the fluid process state (which means whether the fluid state parameters need to be updated and are in a frozen state): when the fluid process parameter is in a frozen state and does not need to be updated, directly taking the fluid process parameter as the fluid process parameter to be output, and sending the fluid process parameter to a subsequent unit; when the fluid process parameters need to be updated and are not in a frozen state, a fluid process parameter updating unit is called to update the fluid process parameters to obtain the fluid process parameters to be output, and the fluid process parameters are sent to a subsequent unit; when the fluid process parameters are not in the frozen state and do not need to be updated, the fluid process parameter storage unit is called to obtain the fluid process parameters which are before the fluid process parameters of the current calculation time step and in the frozen state and the fluid process parameters which are after the fluid process parameters of the current calculation time step and in the frozen state, the fluid process parameters to be output are obtained through calculation, namely, interpolation calculation is carried out on the fluid process parameters of the two frozen states before and after the calculation time step, and the fluid process parameters to be output obtained through interpolation are sent to a subsequent unit. The subsequent units are a calculation control core unit in the interaction and control module and a solid process parameter updating unit in the solid calculation module.
The fluid process state judgment unit, the fluid process parameter updating unit and the fluid process parameter storage unit are combined, and redundant fluid calculation in autoclave process simulation can be remarkably reduced through calculation of flow and unsteady temperature related to the freezing part of fluid, and calculation time is greatly reduced.
The solid calculation module is used for calculating solid process parameters. Specifically, the solid calculation module is used for calculating solid process parameters according to the process parameters of the fluid to be output, wherein the solid process parameters comprise distribution of temperature in time and space, distribution of pressure in time and space and distribution of the curing degree of the workpiece in time and space.
More specifically, the solid state calculation module includes a solid state process parameter updating unit and a solid state process parameter output unit. The solid process parameter updating unit is respectively connected with the fluid process parameter processing and outputting unit, the calculation control core unit and the solid process parameter outputting unit, and the solid process parameter outputting unit is also connected with the calculation control core unit.
And the solid process parameter updating unit is used for calling and utilizing the autoclave construction parameters, the autoclave process model, the autoclave process parameters and the fluid process parameters to be output, calculating the solid process parameters of the current calculation time step by a finite difference method, a finite volume method or a finite element method, and sending the solid process parameters to the solid process parameter output unit. The solid process parameter updating unit of the embodiment is based on the combination of a mathematical computation model and a computer technology, and adopts a finite difference method, a finite volume method or a finite element method to simulate a composite material workpiece in a non-uniform gas flow field in an autoclave process, so that the solid process parameters of the workpiece can be obtained without experiments.
And the solid process parameter output unit is used for sending the solid process parameters to a calculation control core unit in the interaction and control module.
The fluid process parameter updating unit and the solid process parameter updating unit of the embodiment are combined with a computer technology based on a mathematical calculation model, and a finite difference method, a finite element method or a finite volume method is adopted to simulate the curing process of a complex composite material workpiece in the autoclave process, so that the distribution of temperature in time and space, the distribution of pressure in time and space and the distribution rule of the curing degree in time and space in the workpiece can be predicted.
The system of the embodiment is installed in a computer, and the minimum requirements of the computer are that the CPU main frequency is more than 2.0GHz, 4 cores or more, the memory capacity is more than 8G, and the hard disk space is more than 100G. By means of the inherent operational characteristics of the computer, the simulation system of the embodiment is simple and convenient to operate and accurate in simulation result, and can effectively shorten the development period, reduce the development cost and improve the quality of the finished piece through computer simulation. Under the condition of known autoclave construction parameters, finished piece construction parameters and mold construction parameters, the calculation control core unit can call the fluid calculation module to obtain fluid process parameters and call the solid calculation module to obtain solid process parameters by picking up the autoclave process parameters in the process parameter setting unit, and the two process parameters are converted into a format which is easy to read by an operator and a format which is easy to store by a computer through the process parameter output unit, so that a foundation is provided for manufacturing composite material finished pieces with high quality through an autoclave process.
The system of the embodiment is a digital system which is suitable for a composite material autoclave process and utilizes a computer to simulate the temperature change and the curing degree growth rule of a composite material workpiece/workpiece blank under the influence of a non-uniform workpiece boundary caused by non-uniform autoclave working gas flow in a high-efficiency manner, so that the problem of the simulation efficiency of the autoclave process is solved under the condition of considering the simulation accuracy, redundant calculation in a flow field is frozen, and the consumption of calculation and the generation of low-value data are greatly reduced.
Example 3:
by setting the values of the fluid state freezing judgment parameter and the fluid state updating judgment parameter, the state of the fluid process parameter at a certain calculation time step can be judged in any calculation stage, namely, the state can be real-timely calculated to the calculation time step in the simulation process, the state can be judged only when the autoclave process parameter is obtained and any fluid process parameter and solid process parameter are not obtained when the simulation process is not started, and meanwhile, the updating of the fluid process parameter can be executed according to the time sequence of the calculation time step when the calculation time step is reached, or can be executed when the whole simulation process is not started and only the autoclave process parameter is obtained and the solid process parameter is not obtained, and at the moment, the fluid process parameters in all freezing states can be obtained at the beginning of the simulation process. Then, the present embodiment may include two simulation processes, one is: when the simulation process is calculated to the calculation time step, state judgment and fluid process parameter updating are carried out in real time, and the judgment result only comprises that the fluid state parameter belongs to a frozen state, does not need to be updated, needs to be updated and is not in the frozen state; and secondly, before the whole simulation process is started, the fluid state parameters are firstly subjected to state judgment, the judgment result only comprises that the fluid state parameters belong to the frozen state and do not need to be updated, and the fluid state parameters in the frozen state are neither in the frozen state nor in the updated state, and are obtained by calculation at the beginning of the simulation process.
The first simulation process is specifically as follows:
the first step is as follows: the three-dimensional component of the typical composite material autoclave process is picked up in the space configuration and mesh subdivision unit, a two-dimensional cross-sectional schematic diagram of the space occupied by autoclave working gas, a part and a mold can be created in graphical software, so that the observation is convenient, a fluid and solid model with meshes can be obtained in the software, a color three-dimensional picture is displayed on a display screen, and the fluid and solid model with meshes are stored as a data file. The space occupied by the three-dimensional autoclave working gas, a part and a mould (namely three-dimensional fluid space or solid space) are divided into three-dimensional space formed by a limited number of grids, so that data in each grid can be traversed at a later period, and the three-dimensional space with the grids is stored as an autoclave process model for calculation and retrieval.
The second step: in the space configuration and mesh generation unit, auxiliary materials and material parameters thereof used in the process in autoclave construction parameters are input, the types of the auxiliary materials are vacuum bag films, air permeable felts, demolding materials, adhesive blocking strips and sealing tapes, and the material parameters are the types, the using modes, the density, the specific heat capacity and the heat conductivity coefficient of the materials.
The third step: in the space configuration and mesh subdivision unit, the types of materials used by the parts and the material parameters thereof in the construction parameters of the parts are input, the types of the materials used by the parts are carbon fiber, epoxy resin and unidirectional fabric, and the material parameters are the density, specific heat capacity, heat conductivity, curing heat release, curing kinetic model and fiber volume fraction of the materials.
The fourth step: in the space configuration and grid subdivision unit, the type of the material used by the mold and the material parameters thereof in the mold construction parameters are input, the type of the material used by the mold is invar steel, and the material parameters are the density, the specific heat capacity and the heat conductivity coefficient of the material.
The fifth step: extracting autoclave process parameters in a process parameter setting unit, wherein the process parameters comprise 80 ℃ heat preservation for 30min, 120 ℃ heat preservation for 120min, a heating rate of 1.5 ℃/min, a cooling rate of 1.5 ℃/min, a vacuum pressure of-0.1 MPa, and a curing pressure of 0.5MPa after 80 ℃ heat preservation for 30 min.
And a sixth step: and judging whether the simulation time meets t more than or equal to 30000s by using a calculation control core unit, if not, continuing to calculate, and if so, stopping calculating. Each judgment can utilize the technological process parameter output unit to output the technological process parameters of the current and previous calculation time steps.
The seventh step: judging the state of the fluid process parameters of the current time step by using a fluid process state judgment unit, and jumping to the eighth step if the state of the current time step is that the fluid process parameters need to be updated and is not in a frozen state; if the current time step is in a state that the fluid process parameters are in a frozen state and do not need to be updated, jumping to the ninth step;
the eighth step: and reading the autoclave process model, the material type and the material parameter in the first step to the fifth step by using a fluid process parameter updating unit, solving the spatial distribution of the velocity, the spatial distribution of the pressure, the spatial distribution of the density, the spatial distribution of the viscosity and the spatial distribution of the temperature in a fluid region according to a finite volume method, storing relevant data into a fluid process parameter storage unit, sending the relevant data to a fluid process parameter processing and outputting unit, and jumping to the tenth step.
The ninth step: and extracting the spatial distribution of the speed, the spatial distribution of the pressure, the spatial distribution of the density, the spatial distribution of the viscosity and the spatial distribution of the temperature in the frozen state at the current calculation time step by using a fluid process parameter storage unit, sending related data to a fluid process parameter processing and outputting unit, and jumping to the tenth step.
The tenth step: the fluid process parameter processing and outputting unit directly outputs the fluid process parameters to the solid process parameter updating unit and skips to the eleventh step.
The eleventh step: and reading the autoclave process model, the material type and the material parameter in the first step to the fifth step by the solid process parameter updating unit, and solving the spatial distribution of the temperature, the spatial distribution of the pressure and the spatial distribution of the curing degree of the workpiece in the solid area by using a finite element method according to the fluid process parameter transmitted to the solid process parameter updating unit in the tenth step.
A twelfth step: and outputting the solid parameters to a calculation control core unit by using a solid process parameter output unit, and jumping to the sixth step.
The second simulation process is specifically as follows:
the first step is as follows: a typical composite autoclave process three-dimensional component is picked up in a spatial configuration and mesh generation unit. The graphic software can create a two-dimensional cross-sectional schematic diagram of the space occupied by the autoclave working gas, a workpiece and a mold, so that the space, the workpiece and the mold can be observed conveniently, the software can obtain a fluid and solid model with grids, a color three-dimensional picture is displayed on a display screen, and the fluid and solid model with grids are stored as data files. The space occupied by the three-dimensional autoclave working gas, a workpiece and a mould (namely, a three-dimensional fluid space or a solid space) are divided into a three-dimensional space formed by a limited number of grids, so that data in each grid can be traversed at a later period, and the three-dimensional space with the grids is stored as an autoclave process model for calculation and calling.
The second step: in the space configuration and mesh generation unit, auxiliary materials and material parameters thereof used in the process in autoclave construction parameters are input, the types of the auxiliary materials are vacuum bag films, air permeable felts, demolding materials, adhesive blocking strips and sealing tapes, and the material parameters are the types, the using modes, the density, the specific heat capacity and the heat conductivity coefficient of the materials.
The third step: in the space configuration and mesh generation unit, the material types and material parameters of the parts in the part construction parameters are input, the material types of the parts are carbon fibers, epoxy resin and unidirectional fabrics, and the material parameters are the density, specific heat capacity, heat conductivity, curing heat release, curing kinetic model and fiber volume fraction of the material.
The fourth step: in the space configuration and grid subdivision unit, the type of the material used by the mold and the material parameters thereof in the mold construction parameters are input, the type of the material used by the mold is invar steel, and the material parameters are the density, the specific heat capacity and the heat conductivity coefficient of the material.
The fifth step: extracting autoclave process parameters in a process parameter setting unit, wherein the process parameters comprise 80 ℃ heat preservation for 30min, 120 ℃ heat preservation for 120min, a heating rate of 1.5 ℃/min, a cooling rate of 1.5 ℃/min, a vacuum pressure of-0.1 MPa, and curing pressure of 0.5MPa is applied after 80 ℃ heat preservation for 30 min.
And a sixth step: and iteratively updating the fluid process parameters, and acquiring the fluid process parameters in all frozen states at the beginning of the simulation process. And judging whether the simulation time meets t more than or equal to 30000s by using the calculation control core unit, if not, jumping to the seventh step, and if so, jumping to the ninth step.
The seventh step: judging the state of the fluid process parameter of the current time step by using a fluid process state judgment unit, and jumping to the eighth step if the state of the current time step is a frozen state and the fluid process parameter of the frozen state does not exist; if the fluid process parameter of the current time step is in a frozen state but the fluid process parameter of the frozen state exists, jumping to the sixth step; and if the fluid process parameters of the current time step are in a non-frozen state and do not need to be updated, jumping to the sixth step.
Eighth step: and reading the autoclave process model, the material type and the material parameters in the first step to the fifth step by using a fluid process parameter updating unit, solving the spatial distribution of the velocity, the spatial distribution of the pressure, the spatial distribution of the density, the spatial distribution of the viscosity and the spatial distribution of the temperature in a fluid region according to a finite volume method, storing relevant data into a fluid process parameter storage unit, and jumping to the sixth step.
The ninth step: and iteratively updating the solid process parameters. And (5) judging whether the simulation time meets t more than or equal to 30000s by using a calculation control core unit, if not, jumping to the tenth step, and if so, stopping calculation. Each time judgment can utilize the technological process parameter output unit to output the technological process parameters of the current and previous calculation time steps.
The tenth step: judging the state of the fluid process parameters of the current time step by using a fluid process state judgment unit, and jumping to the eleventh step if the state of the current time step is a frozen state and does not need to be updated; and if the fluid process parameters of the current time step are in a non-frozen state and do not need to be updated, jumping to the thirteenth step.
The eleventh step: the fluid process parameter storage unit extracts the spatial distribution of the speed, the spatial distribution of the pressure, the spatial distribution of the density, the spatial distribution of the viscosity and the spatial distribution of the temperature in the current calculation time step in the freezing state, sends related data to the fluid process parameter processing and output unit, and skips to the twelfth step.
A twelfth step: the fluid process parameter processing and outputting unit directly outputs the fluid process parameters to the solid process parameter updating unit, and the fifteenth step is skipped.
The thirteenth step: the fluid process parameter storage unit extracts the spatial distribution of the speed, the spatial distribution of the pressure, the spatial distribution of the density, the spatial distribution of the viscosity and the spatial distribution of the temperature in two freezing states before and after the current calculation time step in time, sends related data to the fluid process parameter processing and outputting unit, and jumps to the fourteenth step.
A fourteenth step of: and the fluid process parameter processing and outputting unit linearly interpolates the spatial distribution of the speed, the pressure distribution, the density distribution, the viscosity distribution and the temperature distribution of the current calculation time step in two frozen states before and after the current calculation time step in time to the current calculation time step according to time, outputs the fluid process parameters obtained by interpolation to the solid process parameter updating unit, and jumps to the fifteenth step.
The fifteenth step: and reading the autoclave process model, the material type and the material parameter in the first step to the fifth step by the solid process parameter updating unit, and solving the spatial distribution of the temperature, the spatial distribution of the pressure and the spatial distribution of the curing degree of the workpiece in the solid area by using a finite element method according to the fluid process parameter transmitted to the solid process parameter updating unit in the twelfth step or the fourteenth step.
Sixteenth step: and outputting the solid parameters to a calculation control core unit by using a solid process parameter output unit, and jumping to the ninth step.
In the present specification, the embodiments are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the foregoing, the description is not to be taken in a limiting sense.
Claims (10)
1. A simulation method for a composite material autoclave process calculated by a freezing part is characterized by comprising the following steps:
carrying out three-dimensional modeling according to the autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, and carrying out mesh generation treatment on the obtained three-dimensional model to obtain an autoclave process model;
taking the autoclave process parameters as the input of the autoclave process model to obtain initial fluid process parameters; the fluid process parameters include a distribution of velocity, pressure, density, viscosity, and temperature in time and space;
judging whether the fluid process parameter is in a frozen state and whether the fluid process parameter needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter;
if the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as a fluid process parameter to be output;
if the fluid process parameter needs to be updated and is not in the frozen state, updating the fluid process parameter to obtain a fluid process parameter to be output;
if the fluid process parameter is not in the frozen state and does not need to be updated, performing interpolation between the fluid process parameter which is before the fluid process parameter and is in the frozen state and the fluid process parameter which is after the fluid process parameter and is in the frozen state to obtain a fluid process parameter to be output;
calculating a solid process parameter according to the process parameter of the fluid to be output; the solid process parameters comprise distribution of temperature, pressure and degree of solidification of the workpiece;
judging whether the simulation stopping time is reached;
if not, taking the fluid process parameter to be output as the fluid process parameter of the next iteration, and returning to the step of judging whether the fluid process parameter is in the frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter.
2. The simulation method according to claim 1, wherein the autoclave construction parameters include a shape of a body of the autoclave, a size of the body, types and material parameters of the working gas, a flow rate of the working gas, a heating manner and a cooling manner; the product construction parameters comprise the shape of the product, the size of the product, the thickness of the product, the layering structure of the pre-forming body, the type of the material used by the product and the material parameters; the mold construction parameters include the shape of the mold, the size of the mold, the thickness of the mold, the type of material used for the mold, and the material parameters.
3. The simulation method according to claim 1, wherein the autoclave process parameters include curing temperature versus time, curing pressure versus time, vacuum pressure versus time, demolding temperature, and process auxiliary materials and material parameters thereof.
4. The simulation method according to claim 1, wherein the fluid state freezing decision parameter includes a maximum time allowed for the fluid to be frozen, a maximum temperature change value from freezing time to current time, a maximum speed change value from freezing time to current time, and a maximum pressure change value from freezing time to current time; the fluid state update decision parameters include a maximum time allowed between two fluid calculation updates, a maximum temperature change value from a last fluid update time to a current time, a maximum speed change value from the last fluid update time to the current time, and a maximum pressure change value from the last fluid update time to the current time.
5. The simulation method according to claim 4, wherein the determining whether the fluid process parameter is in the frozen state and needs to be updated according to the fluid state freezing determination parameter and the fluid state updating determination parameter specifically comprises:
when the time from the freezing moment to the current moment exceeds the longest time for allowing the fluid to be frozen, the temperature change value from the freezing moment to the current moment exceeds the maximum temperature change value from the freezing moment to the current moment, the speed change value from the freezing moment to the current moment exceeds the maximum speed change value from the freezing moment to the current moment or the pressure change value from the freezing moment to the current moment exceeds the maximum pressure change value from the freezing moment to the current moment, the fluid process parameter is not in a frozen state; otherwise, the fluid process parameter is in a frozen state;
when the time from the last fluid updating time to the current time exceeds the longest time between two allowable fluid calculation updates, the temperature change value from the last fluid updating time to the current time exceeds the maximum temperature change value from the last fluid updating time to the current time, the speed change value from the last fluid updating time to the current time exceeds the maximum speed change value from the last fluid updating time to the current time or the pressure change value from the last fluid updating time to the current time exceeds the maximum pressure change value from the last fluid updating time to the current time, the fluid process parameters need to be updated; otherwise, the fluid process parameters do not need to be updated.
6. The simulation method according to claim 1, wherein the updating the fluid process parameter to obtain the fluid process parameter to be output specifically comprises:
and calculating to obtain process parameters of the fluid to be output by using a finite difference method, a finite volume method or a finite element method according to the autoclave construction parameters, the autoclave process model and the autoclave process parameters.
7. The simulation method according to claim 1, wherein the calculating of the solid process parameter from the fluid process parameter to be output comprises:
and calculating the solid process parameters by using a finite difference method, a finite volume method or a finite element method according to the autoclave construction parameters, the autoclave process model, the autoclave process parameters and the fluid process parameters to be output.
8. A composite material autoclave process simulation system for freezing part calculation is characterized by comprising an interaction and control module, a fluid calculation module and a solid calculation module;
the interaction and control module comprises:
the space configuration and mesh generation unit is used for receiving and storing the inputted autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, carrying out three-dimensional modeling according to the autoclave construction parameters, the workpiece construction parameters and the mould construction parameters, and carrying out mesh generation treatment on the obtained three-dimensional model to obtain an autoclave process model;
the process parameter setting unit is used for receiving and storing the input autoclave process parameters;
the calculation control core unit is used for taking the autoclave process parameters as the input of the autoclave process model to obtain initial fluid process parameters; judging whether simulation stop time is reached or not, and controlling the fluid calculation module and the solid calculation module to work by taking a fluid process parameter to be output as a fluid process parameter of the next iteration when the simulation stop time is not reached; the fluid process parameters include distribution of velocity, pressure, density, viscosity and temperature in time and space;
the fluid calculating module is used for judging whether the fluid process parameter is in a frozen state and needs to be updated according to the fluid state freezing judgment parameter and the fluid state updating judgment parameter; if the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as a fluid process parameter to be output; if the fluid process parameters need to be updated and are not in the frozen state, updating the fluid process parameters to obtain fluid process parameters to be output; if the fluid process parameter is not in the frozen state and does not need to be updated, performing interpolation between the fluid process parameter which is before the fluid process parameter and is in the frozen state and the fluid process parameter which is after the fluid process parameter and is in the frozen state to obtain a fluid process parameter to be output;
the solid calculation module is used for calculating solid process parameters according to the process parameters of the fluid to be output; the solid process parameters include the distribution of temperature, pressure and degree of cure of the part in time and space.
9. The simulation system of claim 8, wherein the interaction and control module further comprises a process parameter output unit, and the process parameter output unit is configured to output the to-be-output fluid process parameter and the solid process parameter for each calculation time step obtained in the simulation process, and perform format conversion on the to-be-output fluid process parameter and the solid process parameter into a format that is easy to be read by an operator and/or a format that is easy to be saved by a computer.
10. The simulation system of claim 8, wherein the fluid calculation module comprises:
the fluid process state judging unit is used for judging whether the fluid process parameters are in a frozen state and whether the fluid process parameters need to be updated according to the fluid state freezing judging parameters and the fluid state updating judging parameters;
the fluid process parameter processing and outputting unit is used for processing the fluid process parameters according to the fluid process state; when the fluid process parameter is in a frozen state and does not need to be updated, taking the fluid process parameter as a fluid process parameter to be output; when the fluid process parameter needs to be updated and is not in a frozen state, a fluid process parameter updating unit is called to update the fluid process parameter to obtain a fluid process parameter to be output; when the fluid process parameter is not in the frozen state and does not need to be updated, calling a fluid process parameter storage unit to obtain the fluid process parameter which is in front of the fluid process parameter and in the frozen state and the fluid process parameter which is behind the fluid process parameter and in the frozen state, and calculating to obtain a fluid process parameter to be output;
the fluid process parameter updating unit is used for calling and calculating the process parameters of the fluid to be output by using a finite difference method, a finite volume method or a finite element method according to the autoclave construction parameters, the autoclave process model and the autoclave process parameters;
the fluid process parameter storage unit is used for storing the fluid process parameters in a frozen state.
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