CN115256998A - Method for inhibiting fiber wrinkling during composite component compaction - Google Patents
Method for inhibiting fiber wrinkling during composite component compaction Download PDFInfo
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- CN115256998A CN115256998A CN202210936164.XA CN202210936164A CN115256998A CN 115256998 A CN115256998 A CN 115256998A CN 202210936164 A CN202210936164 A CN 202210936164A CN 115256998 A CN115256998 A CN 115256998A
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- 239000002131 composite material Substances 0.000 title claims abstract description 90
- 238000000034 method Methods 0.000 title claims abstract description 76
- 239000000835 fiber Substances 0.000 title claims abstract description 65
- 238000005056 compaction Methods 0.000 title claims abstract description 28
- 230000002401 inhibitory effect Effects 0.000 title claims abstract description 17
- 238000003475 lamination Methods 0.000 claims abstract description 17
- 238000010008 shearing Methods 0.000 claims abstract description 7
- 230000007547 defect Effects 0.000 abstract description 10
- 230000037303 wrinkles Effects 0.000 abstract description 9
- 230000006835 compression Effects 0.000 abstract description 7
- 238000007906 compression Methods 0.000 abstract description 7
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 238000000465 moulding Methods 0.000 abstract description 3
- 239000007788 liquid Substances 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 238000009826 distribution Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 230000000750 progressive effect Effects 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical group C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 238000012876 topography Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 235000015842 Hesperis Nutrition 0.000 description 1
- 235000012633 Iberis amara Nutrition 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 229920001187 thermosetting polymer Polymers 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
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention discloses a method for inhibiting fiber wrinkling in the compaction process of a composite material member, which is characterized in that the essence of the defect of forming fiber wrinkling in the molding process of the composite material member is that multi-lamination sliding influences each other and cannot be controlled in the compaction process; meanwhile, the fiber stress is released through the shearing motion of fibers in the layer under the condition that the laminated layer is in a slow sliding speed, so that the compression instability of the fibers is avoided; the method solves the problem that the serious wrinkle defect is difficult to control in the forming process of the composite material member, and the design and manufacturing limit of the composite material member with the complex profile structure can be obviously improved.
Description
Technical Field
The invention belongs to the technical field of composite material forming, and particularly relates to a method for inhibiting fiber wrinkling in a composite material member compacting process.
Background
The fiber reinforced resin matrix composite material is light in weight and high in strength, and becomes a preferable material for reducing weight, increasing efficiency and improving performance of aerospace high-end equipment such as large airplanes, fifth-generation fighters, high thrust-weight ratio aircraft engines, heavy carrier rockets and the like. In mainstream pressure forming processes such as autoclave and microwave high-pressure forming, a composite material member with a complex profile structure often has serious fiber wrinkle defects, and is particularly remarkable in an arc area of a member with large thickness. Fiber wrinkling can cause the composite structural properties to deviate significantly from the intended design values, with a 30% reduction in structural compression strength at a 12 ° fiber deviation and a 54% reduction in compression strength at a 22 ° fiber deviation.
In the forming process of the composite material member, in order to ensure that each position of the member can be compacted, a temperature and pressure process curve is preset before solidification, and each position of the member is directly compacted under high pressure in the solidification process. However, under a large gas pressure, each laminate begins to slide at a fast rate in the thickness direction of the composite material, and the laminate tends to be unstable in the out-of-plane direction due to the resistance to sliding in some positions to form wrinkle defects, and further the "avalanche-type" wrinkle defects occur in many positions due to the continuity of the reinforcing fibers. The nature of the formation of fiber crimp defects is that the multiple ply slippage interacts and is not controlled during the compaction process.
The inventor is through careful experiments and theoretical research, proposes that the multi-step pressure triggers each laminated layer in the thickness direction of the composite material to respectively start sliding at different moments, each laminated layer is gradually compacted from outside to inside, disordered laminated sliding is converted into ordered sliding of each laminated layer, and the limitation that the laminated layers simultaneously slide and influence each other in the existing compaction principle is overcome; meanwhile, the fiber stress is released through the shearing motion of fibers in the layer under the condition that the laminated layer is in a slow sliding speed, so that the compression instability of the fibers is avoided; thus, suppression of fiber wrinkling during composite compaction is achieved, which significantly raises the design and manufacturing limits of complex profile structural composite components.
Disclosure of Invention
The invention aims to provide a method for inhibiting fiber wrinkling in a composite material member compacting process, which solves the problem that serious wrinkling defects are difficult to control in a composite material member forming process.
The technical scheme adopted by the invention is that the method for inhibiting fiber wrinkling in the process of compacting the composite material member, the composite material member is arranged on a mould, step pressure is continuously applied to the composite material member from low to high, a slippage interface is generated along the thickness direction of the lamination under each step pressure, the part on the upper side of the slippage interface is compacted by cutting fibers in the layer to be close to the mould surface, the fiber stress is released, the fiber wrinkling is avoided, and the part on the lower side of the slippage interface is kept still; under the subsequent step pressure, the last sliding interface disappears, a sliding new interface is generated from the surface of the composite material member to the side of the mold, the upper side of the new interface is consolidated into a whole and is compacted, and the part of the lower side of the new interface is kept still; repeating the above process until the composite material laminate is compacted; the laminate is progressively stress relieved and densified at multiple times in the thickness direction to inhibit fiber wrinkling during densification of the composite member.
The present invention is also characterized in that,
the number of the step pressure is not less than the repeated times of the layering direction of the composite material member.
The initial value of the step pressure is zero, and the maximum value of the step pressure is the maximum pressure in the pressure forming process of the composite material component.
The pressure increasing rate between two adjacent step pressures is 1-50 KPa/min.
And (3) fluctuating or keeping the pressure value within the range of +/-5% of the current pressure value during step pressure maintaining, wherein the pressure maintaining time between two adjacent step pressures is not less than 2min.
According to the invention the beneficial effects are that:
(1) The method can actively inhibit fiber wrinkling, and avoid the defect of fiber wrinkling in the process of compacting a complex and large-thickness component of a composite material.
(2) The method can gradually compact the composite material member, overcomes the limitation of mutual influence of simultaneous sliding of the laminated layers in the existing compaction principle, and provides a new idea for manufacturing the large-thickness main bearing member.
(3) The method can trigger each lamination in the thickness direction of the composite material to respectively start sliding at different moments by multi-step pressure, and breaks through the thought limitation of compacting a component by large pressure in the existing forming.
(4) The method can release the fiber stress in the compaction process of the composite material member and avoid the wrinkling caused by the compression instability of the reinforced fiber.
Drawings
FIG. 1 is a schematic diagram of the principle of fiber stress formation within a composite layer;
FIG. 2 is a 0 fiber orientation lay-up 13 of a large thickness composite component at 600KPa pressure th ，29 th ,48 th ,64 th Mises stress distribution in (1);
FIG. 3 is the tension in opposite faces of layers of a composite at a constant pressure of 600 KPa;
FIG. 4 is the tension in the opposing faces of each layer of the composite under the multi-step pressure of the method of the present invention;
FIG. 5 is a schematic illustration of a method of inhibiting fiber wrinkling during composite compaction;
FIG. 6 is a schematic illustration of the principle of stress relief when inhibiting fiber wrinkling during composite compaction;
FIG. 7 is a graph comparing the method of the present invention with a prior art compaction strategy;
FIG. 8 is a photograph of the outer surface of a composite part after the part has been formed using the autoclave process;
FIG. 9 is a photograph of the inner surface of a composite part after molding using the autoclave process;
FIG. 10 is a micro-topography of a composite member at the center cross-section and arc locations of the member after being formed using an autoclave process;
FIG. 11 is a photograph of the outer surface of a composite structural member after it has been formed by the method of the present invention;
FIG. 12 is a photograph of the interior surface of a composite structural member after it has been formed by the method of the present invention;
FIG. 13 is a micro-topography of a composite member at the center cross-section and arc locations after being formed by the method of the present invention;
in the figure, 1 is lamination, 2 is pressure, and 3 is a mould.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
The invention provides a method for inhibiting fiber wrinkling in the process of compacting a composite material member, wherein the composite material member is arranged on a mould, step pressure is continuously applied to the composite material member from low to high, a slippage interface is generated in the thickness direction of a lamination under each step pressure, the part on the upper side of the slippage interface is compacted by shearing fibers in a layer and attaching to the mould surface, fiber stress is released, fiber wrinkling is avoided, and the part on the lower side of the slippage interface is kept still; under the subsequent step pressure, the last sliding interface disappears, a sliding new interface is generated from the surface of the composite material member to the side of the mold, the upper side of the new interface is consolidated into a whole and compacted, and the part of the lower side of the new interface is kept still; repeating the above process until the composite material laminate is compacted;
the process gradually compacts each lamination from outside to inside, converts disordered lamination slippage into ordered slippage of each lamination, the laminations are sequentially compacted, only one slippage interface is arranged at each moment, and the limitation that the laminations simultaneously slide and influence each other in the conventional compaction principle is overcome.
At each step pressure, the upper portion of the slip interface is pressed against the mold surface primarily by shearing of fibers in the layer, accommodating the compression characteristics of the stack, and is thus compacted, rather than the conventional multiple stacks sliding over each other. The fibers in the layer are sheared to release the fiber stress, and the fibers are prevented from wrinkling beyond the critical compaction that the reinforcing fibers can bear.
Fiber wrinkling during composite compaction is inhibited due to progressive compaction of the layup and simultaneous fiber stress relief.
The number of the step pressures is determined according to the layering direction of the composite material lamination, the number of the step pressures is not less than the repeated times of the layering direction of the composite material member, and a plurality of laminations in different continuous layering directions are used as a group and compacted under one step pressure. The upper limit of the number of step pressures is the number of composite material stacks, in which case one stack is compacted at one step pressure.
The pressure here refers to the internal pressure of the composite material member forming tank, the initial value of the step pressure is zero, and the maximum value of the step pressure is the maximum pressure in the composite material member pressure forming process.
The pressure increasing rate between two adjacent step pressures is 1-50 KPa/min.
And (3) fluctuating or keeping the pressure value within the range of +/-5% of the current pressure value during step pressure maintaining, wherein the pressure maintaining time between two adjacent step pressures is not less than 2min.
As shown in fig. 1-13.
Example one
This example illustrates the method of inhibiting fiber wrinkling during composite compaction, but is not limited to this example, where a composite spar member of substantial thickness is selected.
The composite spar member is a U-shaped symmetrical structure and is formed by laying 64 layers of unidirectional composite prepreg on a concave die, as shown in figure 1. Under the influence of the geometric curvature, the pressure applied to the surface of the composite component is redistributed as it is transmitted to the interior of the component. Defining the x and y directions of the coordinate system shown in FIG. 1, the pressure exerted by the circular arc area
Can be decomposed into two components of x-direction and y-direction, and the in-plane tension tau of the flat area of the member x From the accumulation of the x-direction pressure component of the circular arc region, and hence τ x Can be expressed as follows:
wherein the content of the first and second substances,
for a positive vector in the direction of application of the pressure P,
is in the x directionThe unit vector ds of (2) is a circular arc region length infinitesimal. According to the above formula, the composite material has an in-plane tension τ x Proportional to the applied pressure P.
The laminated layer sequence of the component is [0 degree, 45 degrees, 90 degrees and-45 degrees ]] 8s Simplified to a modulus of 2X 10 between the stacks 6 And the elastic thin layer of Pa applies a constant pressure field of 600KPa to the composite material member by using a finite element, and analyzes the stress distribution in each lamination layer under different pressure application modes. The first way is to apply a uniform pressure of 600KPa to the surface of the component, with 4 typical 0 fibre direction plies 13 th ，29 th ,48 th ,64 th The stress distribution of Mises in (1) is shown in fig. 2. It can be seen that for composites that can slide between layers, the in-plane tension τ is x The stress is released, transferred and redistributed from the top layer to the bottom layer.
Taking the point A of the flat area of the side wall of the component to analyze the in-plane tension distribution in each layer, and defining the in-plane tension of the opposite surface as the main stress S 11 And an applied pressure of 600 KPa. The internal tension of the facing surfaces of the layers of the composite material at a constant 600KPa pressure is shown in fig. 3, and it can be seen that the internal tension of the facing surfaces is discontinuous in each layer and decreases rapidly from top to bottom, where the 0 ° fiber layer is the largest, the 90 ° fiber layer is the smallest, and the maximum internal tension of the facing surfaces is 0.579.
The second way is to apply a series of step pressures from 0Pa to 600KPa to the component, with a pressure increment step of 30KPa, and a total step pressure time of 12 minutes, simulating the method of the invention, to progressively compact the stack at a slow slip rate. The tension in the opposing faces of each layer of the composite under the multi-step pressure of the method of the present invention is shown in FIG. 4. It can be seen that the opposing surface internal tension during progressive compaction is much less than that of the component under the prior art method of fig. 3, and that the maximum opposing surface internal tension in the inventive method is only 0.0035, which is a 165-fold reduction over the prior art method, demonstrating that fiber stress is significantly reduced by the inventive method.
Schematic diagrams of the method for inhibiting fiber wrinkling during composite material compaction and the stress relief during fiber wrinkling during composite material compaction, as shown in fig. 5-6, based on the above-described compositeApplying a series of step pressures to the member at t 1 Time-to-pressure P on the member 1 At the interface 1, a slip interface SI is formed 1 At a pressure P 1 During the holding process, the tension tau in the plane 1 Under the action, the sliding interface SI 1 The upper laminate is compacted by shearing of the fibers in the layer to achieve partial compaction of the laminate. Further, the pressure is increased to P 2 At the last slip interface SI due to the fibre shear closure of the compacted part 1 Vanishing, a new slip interface SI is created from the vacuum bag side to the mould side 2 The composite material laminate is subdivided into an upper part and a lower part, the upper side of the new interface is consolidated into a whole and compacted, and the lower part of the new interface is kept still. Using a higher pressure P 3 ,P 4 The above process is repeated until the pressure reaches the maximum pressure in the composite pressure forming process, which is determined by the material properties, typically the pressure values recommended by the material manufacturer. Through the process, the composite material member can be gradually compacted in the thickness direction. In the existing pressure forming, a plurality of laminated layers slide to each other to be compacted, in the method, the laminated layers are compacted by fiber shearing in the layers, and the fiber stress is released in the progressive compaction process, so that the fiber is prevented from slipping and being unstable to form wrinkles.
The effectiveness of the method of the present invention in inhibiting fiber wrinkling is verified experimentally below. The raw material of the composite material component is a carbon fiber/epoxy composite material T800/YPH-26 prepreg with the design thickness of 6mm and the laying direction of 0, 45, 90-45] 8s And laying the prepared 64 layers of prepreg on the surface of the concave glass mold layer by layer. And sequentially placing the vacuum auxiliary material on the surface of the composite material component, placing a rubber blocking strip on the edge of the component, packaging a vacuum bag, vacuumizing for 30min in advance, and curing in an autoclave. The temperature process comprises the following steps: heating to 55 deg.C at 1 deg.C/min, maintaining for 60min, heating to 120 deg.C at 1.9 deg.C/min, maintaining for 120min, and naturally cooling, as shown in FIG. 7. Respectively curing under the pressure process of the existing autoclave and the step pressure process of the invention, wherein the pressure applying mode is gas pressure, and the existing pressure process comprises the following steps: increasing the pressure to 6 at 25KPa/min at 45min00KPa, and then maintaining the pressure; the invention relates to a middle step pressure process, which comprises the following steps: the pressure increment step is 30KPa, after 20 increment steps, the pressure is increased to 600KPa, and the pressure increasing rate is 25KPa/min; and (3) when the pressure of each step is maintained, the pressure value fluctuates within the range of +/-5% of the current pressure value, and the pressure maintaining time in each pressure step is 5min.
The quality of the member formed by the two methods is shown in fig. 7. Under the existing autoclave forming method, the outer surface of the component is a profiling surface (as shown in fig. 8), the surface is smooth, serious wrinkle defects are generated in two circular arc areas of the inner surface of the component (as shown in fig. 9), the thickness of the circular arc areas of the component is obviously changed along with wrinkles from the central cross section (as shown in fig. 10) of the component, the maximum thickness deviation can reach 13.1%, and the microscopic view of the circular arc areas shows that serious fiber wrinkles are generated in the component, and the fiber deviation can reach 51 °. The reason is that the autoclave molding often applies a large pressure to the component, each lamination starts to rapidly slide at the same time, the lamination sliding is mutually influenced, and the complicated and disordered sliding is easy to generate the compression instability of the lamination.
However, under the method of the present invention, the outer surface of the member was smooth (as shown in FIG. 11), the inner surface of the member was smooth (as shown in FIG. 12), there were no visible defects, the member had a uniform thickness across the center cross-section (as shown in FIG. 13), and the member was microscopically uniformly layered without fiber wrinkles. The method of the invention effectively inhibits fiber wrinkling during composite member compaction.
Example two
The difference between the embodiment and the embodiment I is that the high-power microwave heating is adopted in the tank body, the method disclosed by the invention is irrelevant to a heating mode, and the method not only can be suitable for a conventional electric heating environment, but also can be suitable for a strong electromagnetic environment. The rest is the same as the first example.
Example three
The difference between the example and the first example is that the material is polyether ether ketone (PEEK)/carbon fiber prepreg, belongs to thermoplastic composite materials, and the method is not only suitable for thermosetting composite materials, but also suitable for thermoplastic composite materials.
Example four
The present example differs from examples one, two, three and four in that the composite member is hyperboloid in shape and 2mm thick.
Example five
The difference between this example and examples one, two and three is that the composite member is heated and pressurized by high temperature and high pressure liquid under liquid pressure in the tank.
Example six
The first difference between this example and examples one, two and three is that the composite member is heated and pressurized by high temperature and high pressure liquid under liquid pressure in the tank; the second difference is: the pressure rise rate between two adjacent step pressures is 1KPa/min.
Example seven
The first difference between this example and examples one, two and three is that the composite member is heated and pressurized by high temperature and high pressure liquid under liquid pressure in the tank; the second difference is: the pressure increasing rate between two adjacent step pressures is 50KPa/min; and keeping the pressure value in the range of +/-5% of the current pressure value during the step pressure maintaining.
The parts not involved in the present invention are the same as or can be implemented using the prior art.
Claims (5)
1. A method for inhibiting fiber wrinkling during the compaction of a composite material member, characterized in that the composite material member is placed on a mould, step pressures are continuously applied to the composite material member from low to high, a slip interface is generated in the thickness direction for each step pressure for lamination, the part on the upper side of the slip interface is compacted by shearing fibers in the layer close to the mould surface, and the part on the lower side of the slip interface is kept still; under the subsequent step pressure, the last sliding interface disappears, a sliding new interface is generated from the surface of the composite material member to the side of the mold, the upper side of the new interface is consolidated into a whole and compacted, and the part of the lower side of the new interface is kept still; the above process is repeated until the composite lay-up is compacted.
2. The method of inhibiting fiber wrinkling during compaction of a composite member according to claim 1, wherein the number of step pressures is not less than the number of repetitions of the lay-up direction of the composite member.
3. The method of inhibiting fiber wrinkling during compaction of a composite member according to claim 1, wherein the initial value of the step pressure is zero and the maximum value of the step pressure is the maximum pressure in the composite member pressure forming process.
4. The method of inhibiting fiber wrinkling during compaction of a composite member according to claim 1, wherein the pressure rise rate between adjacent two step pressures is in the range of 1 to 50KPa/min.
5. The method for inhibiting fiber wrinkling during compaction of a composite member according to claim 1, wherein the step pressure dwell is performed at a pressure value that fluctuates or remains within ± 5% of a current pressure value, and the dwell time between two adjacent step pressures is not less than 2min.
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| CN117525606A (en) * | 2023-11-15 | 2024-02-06 | 西安电子科技大学 | Functional battery with energy supply composite material structure distributed in large space structure and method |
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