CN115256998B - Method for inhibiting fiber wrinkling during compaction of composite components - Google Patents
Method for inhibiting fiber wrinkling during compaction of composite components Download PDFInfo
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- CN115256998B CN115256998B CN202210936164.XA CN202210936164A CN115256998B CN 115256998 B CN115256998 B CN 115256998B CN 202210936164 A CN202210936164 A CN 202210936164A CN 115256998 B CN115256998 B CN 115256998B
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- 239000002131 composite material Substances 0.000 title claims abstract description 90
- 238000000034 method Methods 0.000 title claims abstract description 72
- 239000000835 fiber Substances 0.000 title claims abstract description 62
- 238000005056 compaction Methods 0.000 title claims abstract description 35
- 230000002401 inhibitory effect Effects 0.000 title claims abstract description 16
- 238000010008 shearing Methods 0.000 claims abstract description 8
- 238000000748 compression moulding Methods 0.000 claims 1
- 238000003475 lamination Methods 0.000 abstract description 19
- 230000007547 defect Effects 0.000 abstract description 10
- 230000006835 compression Effects 0.000 abstract description 4
- 238000007906 compression Methods 0.000 abstract description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 230000001960 triggered effect Effects 0.000 abstract description 2
- 238000000465 moulding Methods 0.000 description 9
- 239000007788 liquid Substances 0.000 description 6
- 238000009826 distribution Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 230000000750 progressive effect Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 230000003993 interaction Effects 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
- 230000000630 rising effect 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
- 230000000052 comparative effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 230000002708 enhancing effect Effects 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
- 230000036961 partial effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
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- 229920005989 resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
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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 method for inhibiting fiber wrinkling in the compaction process of the composite material component disclosed by the invention has the advantages that the essence of forming fiber wrinkling defects in the compaction process is that the sliding of multiple laminates is mutually influenced, and the sliding of each laminate in the thickness direction of the composite material is triggered by multi-step pressure and is started at different moments respectively, each laminate is compacted gradually from outside to inside, disordered laminate sliding is converted into ordered sliding of each laminate, and the limitation of simultaneous sliding mutual influence of laminates in the existing compaction principle is overcome; meanwhile, the lamination is ensured to release fiber stress through in-layer fiber shearing movement under the slow sliding rate, so that fiber compression instability is avoided; the method solves the difficult problem that serious fold defects are difficult to control in the forming process of the composite material component, and the design and manufacturing limit of the composite material component with the complex profile structure can be obviously improved.
Description
Technical Field
The invention belongs to the technical field of composite material molding, and particularly relates to a method for inhibiting fiber wrinkling in a composite material component compacting process.
Background
The fiber reinforced resin matrix composite material is light and high in strength, and becomes a preferable material for reducing and enhancing the weight and improving the performance of aerospace high-end equipment such as large aircrafts, fifth-generation fighters, high thrust-weight ratio aeroengines, heavy carrier rockets and the like. In the main stream autoclave, microwave high pressure molding and other molding processes, serious fiber wrinkling defects are often generated in the composite material component with the complex profile structure, and the fiber wrinkling defects are particularly remarkable in the arc area of the component with large thickness. Fiber wrinkling can cause significant deviations from the desired design values for composite structural properties, with a 30% decrease in structural compressive strength when the fibers are 12 ° and a 54% decrease in compressive strength when the fibers are 22 °.
In the process of forming the composite material component, in order to ensure that all positions of the component can be compacted, a temperature and pressure process curve is preset before curing, and all positions of the component are compacted directly under high pressure in the curing process. However, under greater gas pressure, each stack of the composite begins to slip at a faster rate in the thickness direction, and some of the stacks of sites are prone to out-of-plane buckling due to slip resistance, resulting in "avalanche" buckling defects at further locations due to the continuity of the reinforcing fibers. The nature of fiber crimp defect formation is that the multi-ply slip interactions and cannot be controlled during compaction.
Through intensive experiments and theoretical researches, the inventor proposes that each lamination in the thickness direction of the multi-step pressure-triggered composite material starts sliding at different moments respectively, each lamination is compacted gradually from outside to inside, disordered lamination sliding is converted into ordered sliding of each lamination, and the limitation that simultaneous sliding of the lamination in the existing compaction principle is influenced mutually is overcome; meanwhile, the lamination is ensured to release fiber stress through in-layer fiber shearing movement under the slow sliding rate, so that fiber compression instability is avoided; thus, fiber wrinkling is inhibited during compaction of the composite material, which will significantly raise design and manufacturing limits for complex profile structural composite material components.
Disclosure of Invention
The invention aims to provide a method for inhibiting fiber wrinkling during compaction of a composite member, which solves the problem that serious wrinkling defects are difficult to control during the forming process of the composite member.
The technical scheme adopted by the invention is that the method for inhibiting fiber wrinkling in the compaction process of the composite material component comprises the steps that the composite material component is arranged on a die, step pressure is continuously applied to the composite material component from low to high, a sliding interface is generated by lamination under each step pressure along the thickness direction, the part on the upper side of the sliding interface is compacted by shearing fibers in the layer to be close to the die surface, fiber stress is released, fiber wrinkling is avoided, and the part on the lower side of the sliding interface is kept motionless; under the subsequent step pressure, the previous sliding interface disappears, a new sliding interface is generated from the surface of the composite material component to the side of the mould, the upper side of the new interface is solidified 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 lay-up is consolidated; the laminate is progressively stress relieved and compacted at multiple moments in the thickness direction to inhibit fiber wrinkling during compaction of the composite component.
The present invention is also characterized in that,
The number of the step pressures is not less than the number of times the ply direction of the composite member is repeated.
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 rising rate between two adjacent ladder pressures is 1-50 KPa/min.
The pressure value fluctuates or is kept within +/-5% of the current pressure value when the step pressure is maintained, and the pressure maintaining time between two adjacent step pressures is not less than 2min.
The beneficial effects of the invention are as follows:
(1) The method can actively inhibit fiber wrinkling, and avoid fiber wrinkling defects in the compaction process of complex and large-thickness components of the composite material.
(2) The method can gradually compact the composite material component, overcomes the limitation of simultaneous sliding and mutual influence of lamination in the existing compaction principle, and provides a new thought for manufacturing the main bearing component with large thickness.
(3) The method can trigger each lamination in the thickness direction of the composite material to start sliding at different moments by using multi-step pressure, and breaks through the thinking limitation of compacting the component by using high pressure in the existing molding.
(4) The method can release fiber stress in the compaction process of the composite material component, and avoid wrinkling caused by compressive instability of the reinforced fiber.
Drawings
FIG. 1 is a schematic illustration of the principle of fiber stress formation within a composite layer;
FIG. 2 is a Mises stress distribution in a0 fiber direction laminate 13 th,29th,48th,64th for a high thickness composite component at 600KPa pressure;
FIG. 3 is the relative in-plane tension of the composite layers at a constant 600KPa pressure;
FIG. 4 is a graph showing the relative in-plane tension of the layers of the composite material under multi-step pressure in the process 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 stress relief during compaction of a composite while inhibiting fiber wrinkling;
FIG. 7 is a comparative pressure process diagram for the method of the present invention and prior compaction principles;
FIG. 8 is a photograph of the exterior surface of a composite member after being formed using an autoclave process;
FIG. 9 is a photograph of the interior surface of a composite member after being formed using an autoclave process;
FIG. 10 is a microscopic topography of the composite member at the center cross section and circular arc location of the member after molding using an autoclave process;
FIG. 11 is a photograph of the exterior surface of a composite 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 member after molding under the method of the present invention;
FIG. 13 is a graph of the microscopic topography of the composite member at the center cross-section and circular arc location of the member after molding under the method of the present invention;
in the figure, 1. Lamination, 2. Pressure, 3. Mold.
Detailed Description
The invention will be described in detail below with reference to the drawings and the detailed description.
The invention provides a method for inhibiting fiber wrinkling in the compaction process of a composite material component, wherein the composite material component is arranged on a die, step pressure is continuously applied to the composite material component from low to high, a sliding interface is generated by lamination under each step pressure along the thickness direction, the part on the upper side of the sliding interface is compacted by shearing fibers in the layer to be close to the die surface, the fiber stress is released, the fiber wrinkling is avoided, and the part on the lower side of the sliding interface is kept motionless; under the subsequent step pressure, the previous sliding interface disappears, a new sliding interface is generated from the surface of the composite material component to the side of the mould, the upper side of the new interface is solidified 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 lay-up is consolidated;
The process gradually compacts each lamination from outside to inside, the disordered lamination sliding is converted into the ordered sliding of each lamination, the lamination is compacted in sequence, and only one sliding interface exists at each moment, so that the limitation of simultaneous sliding interaction of the lamination in the existing compaction principle is overcome.
At each step pressure, the upper part of the sliding interface is close to the mold surface mainly through in-layer fiber shearing, is suitable for the lamination compression characteristic, and is compacted, rather than the traditional method that a plurality of lamination layers slide between each other to be compacted. The fibers in the layer are sheared to release the fiber stress and avoid wrinkling beyond the critical compaction that the reinforcing fibers can withstand.
Fiber wrinkling is inhibited during composite compaction due to ply progressive compaction and simultaneous fiber stress relief.
The number of the step pressures is determined according to the layering direction of the composite material laminated layers, the number of the step pressures is not less than the number of times of repeating the layering direction of the composite material component, and a plurality of laminated layers with different layering directions are continuously taken as a group to be compacted under one step pressure. The upper limit of the number of step pressures is the number of composite plies, in which case one ply is consolidated under one step pressure.
The pressure here refers to the pressure in the tank formed by the composite material component, 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 rising rate between two adjacent ladder pressures is 1-50 KPa/min.
The pressure value fluctuates or is kept within +/-5% of the current pressure value when the step pressure is maintained, and the pressure maintaining time between two adjacent step pressures is not less than 2min.
As shown in fig. 1-13.
Example one
This example selects a composite spar member of a large thickness to illustrate the method of inhibiting fiber wrinkling during composite compaction, and is not limited to this example.
The composite spar member is of a U-shaped symmetrical structure and is formed by laying 64 layers of unidirectional composite prepregs on a female die, as shown in fig. 1. Under the influence of the geometric curvature, the pressure exerted on the surface of the composite member is redistributed when transferred to the interior of the member. Defining the x and y directions of the coordinate system shown in FIG. 1, the pressure exerted by the circular arc areaThe two components in the x-direction and y-direction can be resolved, and the in-plane Zhang Li x of the flat region of the component results from the accumulation of the x-direction pressure component in the circular arc region, and thus τ x can be expressed as follows:
Wherein, Is a positive vector in the direction of application of the pressure P,The ds is the arc region length infinitesimal, which is the unit vector in the x direction. From the above equation, the in-plane tension τ x of the composite material is proportional to the applied pressure P.
The laminated layers of the component are laminated in the sequence of [0 degree, 45 degree, 90 degree, 45 degree ] 8s, the laminated layers are simplified into an elastic thin layer with the modulus of 2 multiplied by 10 6 Pa, a pressure field with 600KPa constant is applied to the composite component by using finite elements, and the stress distribution in each laminated layer is analyzed under different pressure application modes. The first way is to apply a uniform pressure of 600KPa to the surface of the component, and the Mises stress distribution in the 4 typical 0 ° fiber direction stacks 13 th,29th,48th,64th is shown in fig. 2. It can be seen that for composites that can slide between layers, the stress is released, transferred and redistributed from the top layer to the bottom layer under in-plane tension τ x.
And analyzing the in-plane tension distribution in each layer by taking the point A of the flat area of the side wall of the component, and defining the relative in-plane tension as the ratio of the main stress S 11 to the applied pressure 600 KPa. The relative in-plane tension of each layer of the composite material at a constant 600KPa pressure is shown in fig. 3, and it can be seen that the relative in-plane tension is discontinuous in each layer and decreases rapidly from top to bottom, wherein the 0 ° fiber layer is the largest, the 90 ° fiber layer is the smallest, and the maximum relative in-plane tension is 0.579.
The second way is to apply a series of step pressures from 0Pa to 600KPa to the component, the incremental steps being 30KPa, the total step pressure time being 12 minutes, simulating the method of the present invention, to progressively compact the laminate at a slow slip rate. The relative in-plane tensions of the layers of the composite material under multi-step pressure in the method of the invention are shown in figure 4. It can be seen that the relative in-plane tension during progressive compaction is much less than the tension in the component under the prior art method of fig. 3, and the maximum relative in-plane tension in the method of the present invention is only 0.0035, which is a 165-fold reduction over the prior art method, demonstrating that the fiber stress is significantly reduced by the method of the present invention.
A schematic diagram of a method for inhibiting fiber wrinkling during compaction of a composite material and a schematic diagram of a principle for inhibiting stress release during fiber wrinkling during compaction of a composite material, namely, as shown in fig. 5-6, a series of step pressures are applied to a member based on the characteristic of decreasing tension in a laminated layer surface of the composite material, when pressure P 1 is applied to the member at time t 1, a sliding interface SI 1 is formed at an interface 1, and during the holding of pressure P 1, a laminated layer on the upper side of the sliding interface SI 1 is compacted through shearing of fibers in the layer under the action of in-plane tension τ 1, so that partial compaction of the laminated layer is realized. Further, when the pressure is raised to P 2, the previous slip interface SI 1 disappears due to the fiber shear locking effect of the compacted portion, a new slip interface SI 2 is generated from the side of the vacuum bag to the side of the die, the composite material stack is divided into an upper part and a lower part again, the upper side of the new interface is consolidated into a whole to be compacted, and the lower part of the new interface is kept still. The above process is repeated with a higher pressure P 3,P4 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. Progressive compaction of the composite member in the thickness direction can be achieved by the above process. In the prior pressure forming, the compaction is mainly carried out by mutually sliding a plurality of laminated layers, the compaction is carried out by shearing fibers in layers in the method, and the fiber stress is released in the progressive compaction process, so that the formation of wrinkling caused by sliding and unstability of the fibers is avoided.
The effectiveness of the method of the present invention in inhibiting fiber wrinkling is experimentally verified as follows. The raw material of the composite material component is carbon fiber/epoxy composite material T800/YPH-26 prepreg, the design thickness is 6mm, the layering direction is [0, 45, 90, -45] 8s, and the prepared 64 layers of prepreg are laid on the surface of the concave glass die layer by layer. The vacuum auxiliary materials are sequentially placed on the surface of the composite material component, the rubber blocking strip is placed on the edge of the component, the vacuum bag is packaged, the vacuum bag is pre-vacuumized for 30min, and then the composite material component is solidified in an autoclave. The temperature process is as follows: heating to 55deg.C at 1deg.C/min, maintaining for 60min, heating to 120deg.C at 1.9deg.C/min, maintaining for 120min, and naturally cooling as shown in FIG. 7. Solidifying under the existing autoclave pressure process and the stepped pressure process of the invention respectively, wherein the pressurizing mode is gas pressure, and the existing pressure process is as follows: boosting the pressure to 600KPa at 25KPa/min at 45min, and then maintaining the pressure; the step pressure process comprises the following steps: the pressure increment step is 30KPa, the pressure is increased to 600KPa after 20 increment steps, and the pressure increasing rate is 25KPa/min; the pressure value fluctuates within +/-5% of the current pressure value during pressure maintaining of each step pressure, and the pressure maintaining time in each pressure step is 5min.
The mass of the component formed by the two methods is shown in figure 7. Under the existing autoclave molding method, the outer surface of the component is a profiling surface (shown in fig. 8), the surface is smooth, two arc areas of the inner surface of the component generate serious fold defects (shown in fig. 9), the thickness of the arc area of the component changes obviously along with folds as shown in the central cross section of the component (shown in fig. 10), the maximum thickness deviation can reach 13.1%, and the microscopic image of the arc area can show that serious fiber folds are generated in the component, and the fiber deviation reaches 51 degrees. This is mainly because autoclave molding tends to exert a large pressure on the components, each stack simultaneously begins to rapidly slip, the stack slips interact, and complex disordered slips are extremely prone to stack compression instability.
However, under the method of the present invention, the outer surface of the member is smooth (as shown in fig. 11), the inner surface of the member is smooth (as shown in fig. 12), no visible defects, the thickness of the central cross section of the member is uniform (as shown in fig. 13), and the microscopic laminated distribution is uniform, without fiber wrinkles. The method of the present invention effectively inhibits fiber wrinkling during compaction of composite components.
Example two
The difference between the first example and the first example is that the inside of the tank body is heated by high-power microwaves, and the method is irrelevant to a heating mode, so that the method can be suitable for a conventional electric heating environment and a strong electromagnetic environment. The remainder is the same as in example one above.
Example three
The difference between the first example and the second example is that the material is polyether ether ketone (PEEK)/carbon fiber prepreg, which belongs to thermoplastic composite materials, and the method is not only applicable to thermosetting composite materials, but also applicable to thermoplastic composite materials.
Example four
The difference between this example and examples one, two, three and four is that the composite member is hyperboloid in shape and 2mm in thickness.
Example five
The difference between this example and examples one, two and three is that the liquid pressure in the tank is such that the composite member is heated and pressurized by the high temperature and high pressure liquid.
Example six
The first difference between this example and examples one, two and three is that the tank is pressurized with liquid, and the composite member is heated and pressurized by the high-temperature high-pressure liquid; the second difference is: the rate of pressure increase 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 tank is pressurized with liquid, and the composite member is heated and pressurized by the high-temperature high-pressure liquid; the second difference is: the boosting rate between two adjacent ladder pressures is 50KPa/min; the pressure value is maintained within + -5% of the current pressure value when the step pressure is maintained.
The invention is not related in part to the same as or can be practiced with the prior art.
Claims (3)
1. A method of inhibiting fibre wrinkling during compaction of a composite member, characterized in that the composite member is placed on a mould, stepped pressures are continuously applied to the composite member from low to high, each stepped pressure being such that the stack creates a slip interface in the thickness direction, the upper part of the slip interface being compacted by shearing fibres in the layer against the mould surface, the lower part of the slip interface being held stationary; under the subsequent step pressure, the previous sliding interface disappears, a new sliding interface is generated from the surface of the composite material component to the side of the mould, the upper side of the new interface is solidified 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 lay-up is consolidated;
The boosting rate between two adjacent ladder pressures is 1-50 KPa/min;
The pressure value fluctuates or is kept within +/-5% of the current pressure value when the step pressure is maintained, and the pressure maintaining time between two adjacent step pressures is not less than 2min.
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 component according to claim 1, wherein the step pressure is initially zero and the step pressure maximum is the maximum pressure during the compression molding process of the composite component.
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| CN106042584A (en) * | 2016-01-19 | 2016-10-26 | 南京航空航天大学 | Preparation method for composite laminate product |
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| CN106042584A (en) * | 2016-01-19 | 2016-10-26 | 南京航空航天大学 | Preparation method for composite laminate product |
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