CN116118185A - 3D printing device and method for thermosetting/thermoplastic mixed fiber reinforced composite material - Google Patents
3D printing device and method for thermosetting/thermoplastic mixed fiber reinforced composite material Download PDFInfo
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Abstract
A thermosetting/thermoplastic mixed fiber reinforced composite material 3D printing device and method comprises a material roll device, a tension control device, a yarn spreading device, a fiber presoaking device, a shearing and re-conveying device, a compression roller hot compacting device and an in-situ shaping device which are arranged on a 3D printing motion carrier in sequence; adopting finite element analysis and combining a database to generate a 3D printing path of the thermosetting/thermoplastic hybrid design composite material; inputting a process control code containing path information into a 3D printing device, and impregnating continuous carbon fibers through a resin powder spray gun impregnating a closed cavity to prepare prepreg tows; printing to obtain a preformed body, and performing subsequent heat treatment to obtain a composite material 3D printing forming member; the continuous carbon fiber reinforced thermosetting composite material can realize the preparation of continuous carbon fiber prepreg tows mixed/coated by various resin materials, and can be used for preparing the fiber reinforced composite material by high-efficiency high-quality 3D printing.
Description
Technical Field
The invention relates to the technical field of 3D printing and forming, in particular to a 3D printing device and method for a thermosetting/thermoplastic mixed fiber reinforced composite material.
Background
The composite material has the advantages of high specific strength, high specific modulus, good stability and the like, and is widely applied to the fields of aerospace, automobile manufacturing, ship manufacturing and the like which need strength and pursue light weight. The composite material 3D printing technology is a composite material manufacturing technology with high efficiency, high quality and high customization degree, and can realize the rapid design and manufacture of the composite material. With the continuous development of the 3D printing technology of the composite material, the continuous carbon fiber reinforced thermosetting composite material gradually becomes the main material of the 3D printing of the composite material by virtue of the advantages of high strength, high hardness, good heat resistance and the like.
The existing 3D printing device (application number CN201611026706.0, named as a nozzle suitable for 3D printing of a continuous fiber reinforced composite material) has the following technical scheme that the fiber resin infiltration principle is that molten resin is infiltrated with fibers under the extrusion action, the infiltration scheme is that the time and the flowing length of the resin for wrapping the fiber bundles are increased to improve the bonding effect of the resin and the fiber bundles, and the fiber bundles are directly printed through a nozzle after infiltration is finished; it has the following disadvantages:
(1) The sizing agent is arranged in the fiber tows, and the continuous fibers which are not subjected to yarn spreading presoaked are directly contacted with the resin, so that the resin cannot enter the fiber, and the infiltration is insufficient; (2) Multiple resin mixed printing cannot be realized, and if multiple resin mixed printing is realized by adding a resin tank, the resin in the resin tank behind the first resin tank is polluted by the resin in front; (3) The presoaked tows printed directly through the nozzles can form an included angle of 90 degrees at the nozzles, the nozzles at the positions scratch the fibers, broken fibers are accumulated in the nozzles to cause nozzle blockage, and the nozzles cannot be thermally compacted during printing, so that the printed sample has more defects; (4) Resin in a container of the molten resin of the device is difficult to recover and clean, so that the resin is wasted, and the resin is polluted when the resin is replaced; (5) After the sample is printed, the fiber tows need to be manually cut off for reprinting, and the degree of automation is low.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide a 3D printing device and a method for a thermosetting/thermoplastic mixed fiber reinforced composite material, which can realize the preparation of continuous carbon fiber prepreg tows mixed/coated by various resin materials and perform high-efficiency high-quality 3D printing to prepare the fiber reinforced composite material.
In order to achieve the purpose, the invention adopts the following technical scheme:
a thermosetting/thermoplastic mixed fiber reinforced composite material 3D printing device comprises a material roll device, a tension control device, a yarn spreading device, a fiber presoaking device, a shearing and re-conveying device, a compression roller hot compacting device and an in-situ shaping device which are arranged on a 3D printing motion carrier in sequence;
the material roll device comprises a material roll, and a continuous carbon fiber material roll is wound on the material roll;
the tension control device comprises a height-adjustable roller and a fixed roller, and the wrap angle of the continuous carbon fiber tows on the roller is adjusted through height change to control the tension of the continuous carbon fibers;
the yarn spreading device comprises a high-temperature compressed gas device, and softens sizing agent in the continuous carbon fiber at high temperature to finish yarn spreading of the continuous carbon fiber;
the fiber presoaking device comprises more than one dipping closed cavity, wherein two ends of the dipping closed cavity are provided with calcium carbide rollers, continuous carbon fibers form a conductive path, and heating of continuous carbon fiber tows is completed; a temperature sensor is arranged in the dipping closed cavity, and the temperature sensor detects the temperature of the continuous carbon fiber tows; the graphite roller, the control end of the temperature sensor and the temperature controller are connected, the temperature controller regulates and controls the current in the continuous carbon fiber tows through the signals of the temperature sensor, so that the temperature control of the continuous carbon fiber tows in the dipping closed cavity is realized, and the temperature is higher than the softening point of the selected resin; the resin powder spray gun connected in the dipping closed cavity sprays mixed resin powder to the continuous carbon fiber tows, the mixed resin powder is softened rapidly after contacting with high-temperature continuous carbon fibers and is attached to the continuous carbon fibers, and the dipping of the continuous carbon fiber reinforced composite material is completed;
the shearing and re-conveying device comprises a shearing device and a pair of rollers, and is used for shearing, clamping and re-conveying the continuous carbon fiber tows;
the compression roller of the compression roller thermal compaction device is heated by a heating rod, and continuous carbon fiber tows sent by the shearing and re-sending device are softened after contacting with the hot-pressing roller, contact with the printing bottom plate along with the compression roller, and are adhered to the printing bottom plate through the hot compaction function of the compression roller;
and the in-situ setting device sets the continuous carbon fibers on the printing bottom plate in situ to finish printing.
The yarn spreading device is replaced by an ultrasonic yarn spreading device and a mechanical yarn spreading device according to the requirement.
The 3D printing motion carrier comprises a robot type motion mechanical carrier, a gantry type motion mechanical carrier, a horizontal motion mechanical carrier and a motion mechanical carrier with different mixed structures.
The surface of the pressing roller hot compacting device is provided with a temperature sensor, so that the accurate control of the surface temperature of the pressing roller is realized.
The in-situ shaping device is a device for providing energy required by thermoplastic and thermosetting in-situ shaping by an electron beam curing cavity, a photo-curing light source and a laser light source.
The number of the impregnation closed cavities and the matched devices thereof is increased or decreased according to the required properties of the composite material, and the resin is presoaked, or the impregnation of more than two resins is realized, so that the thermoplastic resin-coated thermosetting resin continuous carbon fiber reinforced tows or thermosetting resin-coated thermoplastic resin continuous carbon fiber reinforced tows and other multi-layer resin composite material presoaked tows are formed; the interlaminar performance of the continuous carbon fiber reinforced thermosetting composite material is improved, the curing temperature is controlled below the softening point of the thermoplastic resin in the curing process, and the thermoplastic resin is utilized to maintain the shape in the curing process, so that the die-free curing is realized.
The vacuum recovery device is attached in the dipping closed cavity, and can recover and recycle the redundant resin powder; 1-4 resin powder spray guns are arranged in the dipping closed cavity according to the width requirement of the continuous carbon fiber tows, and inert gases such as nitrogen, argon and the like are introduced into the dipping closed cavity for the resin requiring inert environment; the power of the printing heating power supply is 20-1000W, and the amplitude current of 0-100A is provided, so that the heating temperature of 50-500 ℃ is realized.
A printing method using a thermosetting/thermoplastic hybrid fiber reinforced composite 3D printing device, comprising the steps of:
s1: according to the structural performance requirement of the composite material, adopting finite element analysis to optimize the composite material structure to obtain a composite material structure with mixed and matched thermosetting/thermoplastic resin matrixes, and combining a composite material performance database to select the composite material resin matrixes required by different positions so as to generate a 3D printing path of the thermosetting/thermoplastic mixed design composite material;
s2: loading the required thermosetting and/or thermoplastic resin matrix into resin powder spray gun, and loading selected continuous carbon fiber tows into material winding device;
s3: the printing process parameters including printing speed, printing temperature, pressing roller temperature and height, tow tension, prepreg tow control instruction and shearing and re-conveying control instruction are preset by combining the printing path generation and the composite material printing performance requirements;
s4, inputting a process control code containing path information into a control system of a 3D printing device to start printing, enabling continuous carbon fibers to enter an impregnation closed cavity after yarn spreading, spraying resin powder through a resin powder spray gun to form a resin/multi-resin pre-soaked tows, and performing thermal compaction through a compression roller to obtain a composite material 3D printing preformed body with a mixed design;
s5: and (3) according to the requirements of thermosetting resin post-curing and thermoplastic resin heat treatment, placing the prepared preformed body in a temperature environment required by mixed resin for subsequent heat treatment, and finally obtaining the composite material 3D printing and forming component.
The finite element solving software in the step S1 comprises ANSYS, ABAQUS, MATLAB, COMSOL, icepark, flotherm, microWave Studio, HFSS or Mafia.
The control of the prepreg effect of the printing tows in the step S3 is realized by controlling the heating temperature and the powder spraying amount of the prepreg tows, wherein the heating temperature of the prepreg tows is controlled by regulating the voltage of graphite electrode rollers at two ends of the continuous carbon fiber tows, and the powder outlet amount sprayed by the resin powder spray gun is regulated by regulating the electrostatic nozzle size and the electrostatic voltage of the resin powder spray gun, so that the prepreg effect of different resin matrixes and different resin contents is controlled.
The beneficial effects of the invention are as follows:
because the invention adopts the scheme of spreading yarn and presoaking, the invention has the advantage of full infiltration of continuous fibers and resin, and the fiber can be widened by controlling the tension of the continuous fibers, thereby facilitating the subsequent spreading yarn and infiltration;
because the resin powder is pre-soaked in a mode of spraying resin powder by the resin powder spray gun and the continuous carbon fibers are heated in a current mode, the invention has the advantages of uniform fiber resin distribution, adjustable resin content of the pre-soaked tows, capability of realizing thermosetting/thermoplastic resin mixing/coating of the continuous fiber pre-soaked tows and the like;
according to the invention, as the soaking scheme of spraying powder by the resin powder spray gun in the soaking closed cavity is adopted, the powder is fused and adhered to the continuous carbon fiber after contacting the high-temperature continuous carbon fiber, and the residual powder which is not adhered to the continuous fiber is automatically deposited at the bottom of the soaking closed cavity, the residual resin powder can be recovered by the schemes of arranging a dust collection device, arranging a hopper recovery device at the bottom of the soaking closed cavity and the like;
according to the invention, as the resin powder spray gun is adopted to spray the resin powder on the continuous carbon fiber for soaking, the resin powder is stored in the powder barrels of the resin powder spray gun, and the powder barrels of the two resin powder spray guns can be changed along with the printing process, so that the effect of changing the resin is realized, the resin of the continuous fiber reinforced composite material is changed during the printing process, the resin can be changed along with the printing at any time, the shutdown is not needed, and the degree of automation is high;
the invention adopts the soaking scheme of two soaking closed cavities, so that the invention has the advantage that the preparation of the prepreg tows mixed by various resin materials can be realized, the prepreg tows prepared by the first soaking closed cavity can not influence the recovery of the resin powder in the second soaking closed cavity when entering the second soaking closed cavity, the resin powder materials in the two soaking closed cavities can be selected according to the needs, and the number of the soaking closed cavities can be increased and decreased according to the needs; the switching between single material and double-layer material can be realized, and the printing of different resin materials can be realized; according to the invention, the continuous carbon fiber tows are soaked by the resin powder spray guns in two different soaking closed cavities, the resin materials in two environments are not doped with each other, the recycling of the resin powder can be realized, and the material utilization rate is high;
according to the invention, due to the integrated design of the material roll device, the tension control device, the yarn spreading device, the fiber pre-soaking device, the shearing and re-conveying device, the compression roller hot compacting device and the in-situ shaping device, the integrated continuous fiber reinforced 3D printing can be realized, and the printing device can be arranged on a required platform according to the requirement, so that the manufacturing efficiency of the composite material is improved.
The preparation of the continuous carbon fiber reinforced composite material prepreg tows is completed by utilizing the fiber prepreg device, the internal and external materials of the prepreg tows are determined according to the needs, and can be thermosetting and/or thermoplastic resin to form a two-layer resin structure, so that the application range of the 3D printing technology of the continuous carbon fiber reinforced composite material is expanded, and the problems that the interlayer performance of the fiber reinforced thermosetting composite material printed by the traditional manufacturing method is poor, the strength of the fiber reinforced thermoplastic composite material is low due to deformation in the curing process, the high temperature resistance is difficult and the like are solved; compared with the traditional composite material 3D printing, the invention can print composite materials mixed with various resin materials, can realize coating printing of different resins, has no doping between the two resins, can ensure the recycling of resin powder, completes the preparation of one or two resin material coating prepreg tows of the continuous carbon fiber reinforced composite material, the shearing clamping and the heavy feeding, the compression roller hot compaction and the in-situ shaping of the composite material, and can be used for manufacturing the automatic manufacturing of the continuous carbon fiber reinforced composite material mixed with various resin materials.
Drawings
Fig. 1 is a schematic structural view of an embodiment of the present invention.
FIG. 2 is a schematic cross-sectional view of a fiber tow of continuous carbon fibers after infiltration in accordance with an embodiment of the present invention.
FIG. 3 is a graph showing the adhesion effect of the resin powder particles to the continuous carbon fiber according to the embodiment of the present invention.
FIG. 4 is a cross-sectional electron microscope of a prepreg continuous carbon fiber tow according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings.
Referring to fig. 1, a 3D printing device for a thermosetting/thermoplastic mixed fiber reinforced composite material comprises a material roll device, a tension control device, a yarn spreading device, a fiber presoaking device, a shearing and re-conveying device, a compression roller hot compacting device and an in-situ shaping device which are arranged on a 3D printing motion carrier in sequence;
the material rolling device comprises a material rolling roller, wherein a continuous carbon fiber material roll 1 is wound on the material rolling roller, and continuous carbon fibers enter the tension control device;
the tension control device comprises a first height-adjustable roller 2, a second height-adjustable roller 4, a third height-adjustable roller 5 and a fixed roller 3 with unchanged height; the first height-adjustable roller 2 and the fixed roller 3 form a pair of rollers, the distance between the two rollers is changed by adjusting the height of the first height-adjustable roller 2, and the wrap angle of the fiber and the rollers is adjusted, so that the clamping force on the continuous carbon fiber tows is adjusted, and the phenomenon of negligence of the fiber tension caused by uneven mass distribution of the continuous carbon fiber roll 1 is prevented; the second height-adjustable roller 4 and the third height-adjustable roller 5 can adjust the heights, and the wrap angles of the continuous carbon fiber tows on the rollers are adjusted through the height change, so that the tension of the continuous carbon fibers is controlled, and the adjusted continuous carbon fibers enter a yarn spreading device;
the yarn spreading device comprises a high-temperature compressed gas device 6, compressed gas is heated by heating, and sizing agent in the continuous carbon fiber is softened at high temperature, so that the high-temperature compressed gas easily blows open the continuous carbon fiber, yarn spreading of the continuous carbon fiber is completed, and preparation is made for subsequent infiltration; the yarn spreading device can be replaced by other devices such as an ultrasonic yarn spreading device, a mechanical yarn spreading device and the like as required;
the fiber presoaking device comprises a first dipping airtight cavity 8, wherein a first graphite passing roller 7 and a second graphite passing roller 11 are arranged at two ends of the first dipping airtight cavity 8, and the first graphite passing roller 7 and the second graphite passing roller 11 form a conductive path for the middle continuous carbon fiber by utilizing the conductivity of the continuous carbon fiber so as to finish heating the continuous carbon fiber tows; a first temperature sensor 10 is arranged in the first soaking closed cavity 8, and the first temperature sensor 10 detects the temperature of the continuous carbon fiber tows; the first graphite passing roller 7, the second graphite passing roller 11, the control end of the first temperature sensor 10 and the first temperature controller 18 are connected, and the first temperature controller 18 regulates and controls the current in the continuous carbon fiber tows through the signal of the first temperature sensor 10, so that the temperature control of the continuous carbon fiber tows in the first dipping closed cavity 8 is realized, and the temperature is higher than the softening point of the selected resin; the first resin powder spray gun 9 connected in the first impregnation closed cavity 8 sprays mixed resin powder to the high-temperature continuous carbon fiber tows after yarn spreading, the mixed resin powder is quickly softened after contacting with the high-temperature continuous carbon fibers and is adhered to the continuous carbon fibers, and the mixed resin and the continuous carbon fibers are fully soaked in the process due to full spreading after yarn spreading of the continuous carbon fibers, so that the first-layer soaking of the continuous carbon fiber reinforced composite material is completed;
the infiltrated continuous carbon fiber tows leave the second graphite roller 11 and then pass through the compressed gas device 12, and the compressed gas sprayed by the compressed gas device 12 can cool the thermosetting resin (hybrid resin) attached on the continuous carbon fiber tows; if desired, the compressed gas device 12 may be replaced with other devices to assist in cooling the continuous carbon fiber tow, depending on the desired conditions;
the cooled continuous carbon fiber tows are subjected to second-layer impregnation through a second impregnation closed cavity 14; the third and fourth graphite rollers 13 and 17 are arranged at two ends of the second dipping airtight cavity 14, and the third and fourth graphite rollers 13 and 17 form a conductive path with the middle continuous carbon fiber by utilizing the conductivity of the continuous carbon fiber so as to finish heating the continuous carbon fiber tows; a second temperature sensor 16 is arranged in the second soaking closed cavity 14, and the second temperature sensor 16 detects the temperature of the continuous carbon fiber tows; the third and fourth graphite rollers 13 and 17 and the control end of the second temperature sensor 16 are connected with the second temperature controller 19, and the second temperature controller 19 regulates and controls the current in the continuous carbon fiber tows through the signal of the second temperature sensor 16, so that the temperature control of the continuous carbon fiber tows in the second dipping closed cavity 14 is realized, and the temperature is higher than the softening point of the selected resin;
the second resin powder spray gun 15 connected with the second dipping airtight cavity 14 sprays selected resin powder to the continuous carbon fiber tows which are soaked with a layer of resin and high temperature, the resin powder is quickly softened after contacting the high temperature continuous carbon fiber tows and is adhered to the continuous carbon fibers soaked with the resin, the resin in the first resin powder spray gun 9 and the resin in the second resin powder spray gun 15 are arranged in the continuous carbon fibers, and a layer of resin film is formed on the surfaces of the continuous carbon fiber tows after spraying and adsorbing, so that the second dipping of the continuous carbon fiber reinforced composite material is completed; the section of the infiltrated continuous carbon fiber tows is shown in fig. 2, wherein the continuous carbon fibers 25 are fully unfolded, the inside and the surface of the continuous carbon fibers 25 are filled with a first resin 26 in a first resin powder spray gun 9, the surface of the first resin 26 is wrapped with a layer of a second resin 27 in a second resin powder spray gun 15, and one or more resin matrix continuous carbon fiber reinforced composite material prepreg tows are prepared; in addition, the number of the soaking closed cavities and the matched devices can be increased or decreased according to the required properties of the composite material, the presoaking of one resin can be carried out, and the soaking of more than two resins can be realized. The fiber prepreg device can realize the preparation of various requirements of prepreg tows, for example, thermosetting resin powder mixed with a thermal initiator is placed in a first resin powder spray gun 9, thermoplastic resin powder with a softening point higher than that of the thermosetting resin is placed in a second resin powder spray gun 15 to form continuous carbon fiber reinforced tows with the thermosetting resin wrapped by the thermoplastic resin, the method can improve the interlaminar performance of the continuous carbon fiber reinforced thermosetting composite material, the curing temperature is controlled below the softening point of the thermoplastic resin in the curing process, and the shape in the curing process is kept by the thermoplastic resin to realize the die-free curing; the fiber prepreg device can also realize the replacement of resin materials in the printing process of the same sample, for example, flexible resin is added into the powder barrel of the spray gun when the inner layer of the sample is printed, the powder barrel is replaced after the inner layer of the sample is printed, the flexible resin in the powder barrel is replaced with resin with high rigidity, and the outer layer of the sample is printed.
The presoaked continuous carbon fiber enters a shearing and re-conveying device, wherein the shearing and re-conveying device comprises a first pair of rollers 20, a shearing device 21 and a second pair of rollers 22 which are sequentially arranged, and the first pair of rollers 20 and the second pair of rollers 21 are driven by a motor; the shearing device 21 can realize the shearing of the continuous carbon fiber tows, the first pair of rollers 20 clamps the continuous carbon fiber tows to be conveyed downwards after the shearing, and the continuous carbon fiber tows are conveyed to the second pair of rollers 22, so that the shearing, clamping and re-conveying of the continuous carbon fiber tows are completed, and the automatic printing of the continuous carbon fiber reinforced composite material is completed;
the compression roller of the compression roller thermal compaction device 23 is heated by a heating rod, a temperature sensor is arranged on the surface temperature of the compression roller, the accurate control of the surface temperature of the compression roller can be realized, the continuous carbon fiber tows sent by the shearing and re-conveying device are softened after contacting the hot-pressing roller, and the continuous carbon fiber tows are contacted with the printing bottom plate along with the compression roller and are adhered to the printing bottom plate by the hot-pressing function of the compression roller;
the in-situ shaping device 24 (which may be an electron beam curing chamber, a photo-curing light source, a laser light source, or the like, which provides the energy required for thermoplastic and thermosetting in-situ shaping) performs in-situ shaping on the continuous carbon fibers on the printing substrate, and completes the final printing.
The 3D printing motion carrier comprises a robot type motion mechanical carrier, a gantry type motion mechanical carrier, a horizontal motion mechanical carrier and a motion mechanical carrier with different mixed structures.
Before printing starts, the composite material structure is optimized by adopting finite element analysis according to the mechanical properties of the composite material, the composite material structure with the mixed collocation of thermosetting/thermoplastic resin matrixes is obtained, the composite material resin matrixes required by different positions are selected, and the required resin matrix materials are prepared into powder and then added into the corresponding first resin powder spray gun 9 and the second resin powder spray gun 15.
A printing method using a thermosetting/thermoplastic hybrid fiber reinforced composite 3D printing device, comprising the steps of:
s1: optimizing the composite material structure by adopting finite element analysis according to the structural performance requirement of the composite material to obtain a composite material structure with mixed and matched thermosetting/thermoplastic resin matrixes, and then selecting the composite material resin matrixes required by different positions by combining a composite material performance database to generate a 3D printing path of the thermosetting/thermoplastic mixed design composite material;
s2: based on the composite material mixing design result, loading the required thermosetting and/or thermoplastic resin matrix into the first resin powder spray gun 9 and the second resin powder spray gun 15 respectively, and then loading the selected continuous carbon fiber tows into a material winding device;
s3: the printing process parameters including printing speed, printing temperature, pressing roller temperature and height, filament tension, prepreg filament control instructions, shearing and re-feeding control instructions and the like are preset by combining the printing path generation and the printing performance requirements of the composite material; the printing speed is set through a motor of a motion mechanism of the 3D printer, the printing temperature is controlled through a heating system on a press roller, the temperature and the height of the press roller are controlled through a press roller cylinder and the heating system, and the shearing and re-conveying instruction is controlled through an extrusion motor and shearing scissors according to a preset re-conveying position in a printing path; the presoaked fiber bundle control command sprays resin powder onto the surface of the electrically heated carbon fiber bundles through a resin powder spray gun, and the resin and the continuous carbon fibers are quickly fused to achieve a uniform and quick impregnation effect;
s4, inputting a process control code containing path information into a control system of a 3D printing device to start printing, wherein a material roll device contains continuous carbon fibers as printing tows, the drawn continuous carbon fiber tows firstly pass through a tension control device and then pass through a yarn spreading device to spread yarns, then pass through a fiber presoaking device to select and impregnate with thermosetting and/or thermoplastic resin to realize presoaked tows with thermosetting and/or thermoplastic resin mixed design, the prepared continuous carbon fiber presoaked tow printing material realizes the control of the cutting and re-conveying functions of the fiber tows through a cutting re-conveying device, then passes through a compression roller thermal compacting device to carry out thermal compaction, an in-situ shaping device carries out in-situ pre-curing on the extruded thermosetting resin to print or enables the thermoplastic resin to carry out recrystallization deformation, and the processes are circulated to print layer by layer, so that the 3D printing preformed body of the composite material with mixed design is obtained;
s5: and (3) according to the requirements of thermosetting resin post-curing and thermoplastic resin heat treatment, placing the prepared preformed component in a temperature environment required by mixed resin for subsequent heat treatment, and finally obtaining the composite material 3D printing and forming component.
The finite element solving software in the step S1 comprises ANSYS, ABAQUS, MATLAB, COMSOL, icepark, flotherm, microWave Studio, HFSS or Mafia, establishes a mapping relation between pseudo density and performance parameters to obtain a performance content value of each unit, and brings the value into an anisotropic material constitutive model by combining fiber angles to obtain material properties of each unit so as to realize structure optimization iteration.
In the step S2, the thermosetting resin is epoxy resin, unsaturated polyester, cyanate ester, bismaleimide resin, phenolic resin and mixtures thereof, and the thermoplastic resin is polypropylene, polylactic acid, polyether ether ketone, polydimethylsiloxane, silicone rubber and mixtures thereof or thermoplastic and thermosetting mixed resin.
The control of the prepreg effect of the printing tows in the step S3 is realized by controlling the heating temperature and the powder spraying amount of the prepreg tows, wherein the heating temperature of the prepreg tows is controlled by regulating the voltage of graphite electrode rollers at two ends of the continuous carbon fiber tows, and the powder outlet amount sprayed by the resin powder spray gun is regulated by regulating the electrostatic nozzle size and the electrostatic voltage of the resin powder spray gun, so that the prepreg effect of different resin matrixes and different resin contents is controlled.
The invention realizes 3D printing of continuous carbon fiber reinforced multi-resin matrix composite materials, can finish 3D printing coated by the same resin or different resins, has high integration degree, can automatically print, has good printing quality, and realizes the integrated manufacture of multiple materials. The carbon fibers and the resin of the prepreg tows which are subjected to the two soaking closed cavities are uniformly distributed and tightly combined, the adhesion effect diagram of the resin powder particles and the continuous carbon fibers is shown in fig. 3, and the section electron microscope diagram of the prepreg tows of the vegetation after heating is shown in fig. 4. According to the invention, the traditional single-material composite material 3D printing technology is expanded into a 3D printing technology coated by a plurality of resin materials, and the printed residual resin powder particles cannot be in direct contact with each other, so that the recycling of the resin powder can be realized.
Claims (10)
1. A thermoset/thermoplastic hybrid fiber reinforced composite 3D printing device, characterized by: the device comprises a material roll device, a tension control device, a yarn spreading device, a fiber presoaking device, a shearing and re-conveying device, a compression roller hot compacting device and an in-situ shaping device which are arranged on a 3D printing motion carrier in sequence;
the material roll device comprises a material roll, and a continuous carbon fiber material roll is wound on the material roll;
the tension control device comprises a height-adjustable roller and a fixed roller, and the wrap angle of the continuous carbon fiber tows on the roller is adjusted through height change to control the tension of the continuous carbon fibers;
the yarn spreading device comprises a high-temperature compressed gas device, and softens sizing agent in the continuous carbon fiber at high temperature to finish yarn spreading of the continuous carbon fiber;
the fiber presoaking device comprises more than one dipping closed cavity, wherein two ends of the dipping closed cavity are provided with calcium carbide rollers, continuous carbon fibers form a conductive path, and heating of continuous carbon fiber tows is completed; a temperature sensor is arranged in the dipping closed cavity, and the temperature sensor detects the temperature of the continuous carbon fiber tows; the graphite roller, the control end of the temperature sensor and the temperature controller are connected, the temperature controller regulates and controls the current in the continuous carbon fiber tows through the signals of the temperature sensor, so that the temperature control of the continuous carbon fiber tows in the dipping closed cavity is realized, and the temperature is higher than the softening point of the selected resin; the resin powder spray gun connected in the dipping closed cavity sprays mixed resin powder to the continuous carbon fiber tows, the mixed resin powder is softened rapidly after contacting with high-temperature continuous carbon fibers and is attached to the continuous carbon fibers, and the dipping of the continuous carbon fiber reinforced composite material is completed;
the shearing and re-conveying device comprises a shearing device and a pair of rollers, and is used for shearing, clamping and re-conveying the continuous carbon fiber tows;
the compression roller of the compression roller thermal compaction device is heated by a heating rod, and continuous carbon fiber tows sent by the shearing and re-sending device are softened after contacting with the hot-pressing roller, contact with the printing bottom plate along with the compression roller, and are adhered to the printing bottom plate through the hot compaction function of the compression roller;
and the in-situ setting device sets the continuous carbon fibers on the printing bottom plate in situ to finish printing.
2. The apparatus according to claim 1, wherein: the yarn spreading device is replaced by an ultrasonic yarn spreading device and a mechanical yarn spreading device according to the requirement.
3. The apparatus according to claim 1, wherein: the 3D printing motion carrier comprises a robot type motion mechanical carrier, a gantry type motion mechanical carrier, a horizontal motion mechanical carrier and a motion mechanical carrier with different mixed structures.
4. The apparatus according to claim 1, wherein: the surface of the pressing roller hot compacting device is provided with a temperature sensor, so that the accurate control of the surface temperature of the pressing roller is realized.
5. The apparatus according to claim 1, wherein: the in-situ shaping device is a device for providing energy required by thermoplastic and thermosetting in-situ shaping by an electron beam curing cavity, a photo-curing light source and a laser light source.
6. The apparatus according to claim 1, wherein: the number of the impregnation closed cavities and the number of the matched devices are increased or decreased according to the required properties of the composite material, and the resin is pre-soaked, or the impregnation of more than two resins is realized, so that the continuous carbon fiber reinforced tows with thermoplastic resin coated with thermosetting resin or the composite material pre-soaked tows with multi-layer resin with the continuous carbon fiber reinforced tows with thermosetting resin coated with thermoplastic resin are formed.
7. The apparatus according to claim 1, wherein: the vacuum recovery device is attached in the dipping closed cavity, and can recover and recycle the redundant resin powder; 1-4 resin powder spray guns are arranged in the dipping closed cavity according to the width requirement of the continuous carbon fiber tows, and inert gases such as nitrogen, argon and the like are introduced into the dipping closed cavity for the resin requiring inert environment; the power of the printing heating power supply is 20-1000W, and the amplitude current of 0-100A is provided, so that the heating temperature of 50-500 ℃ is realized.
8. A printing method using the thermosetting/thermoplastic hybrid fiber reinforced composite material 3D printing device of any one of claims 1 to 7, comprising the steps of:
s1: according to the structural performance requirement of the composite material, adopting finite element analysis to optimize the composite material structure to obtain a composite material structure with mixed and matched thermosetting/thermoplastic resin matrixes, and combining a composite material performance database to select the composite material resin matrixes required by different positions so as to generate a 3D printing path of the thermosetting/thermoplastic mixed design composite material;
s2: loading the required thermosetting and/or thermoplastic resin matrix into resin powder spray gun, and loading selected continuous carbon fiber tows into material winding device;
s3: the printing process parameters including printing speed, printing temperature, pressing roller temperature and height, tow tension, prepreg tow control instruction and shearing and re-conveying control instruction are preset by combining the printing path generation and the composite material printing performance requirements;
s4, inputting a process control code containing path information into a control system of a 3D printing device to start printing, enabling continuous carbon fibers to enter an impregnation closed cavity after yarn spreading, spraying resin powder through a resin powder spray gun to form a resin/multi-resin pre-soaked tows, and performing thermal compaction through a compression roller to obtain a composite material 3D printing preformed body with a mixed design;
s5: and (3) according to the requirements of thermosetting resin post-curing and thermoplastic resin heat treatment, placing the prepared preformed body in a temperature environment required by mixed resin for subsequent heat treatment, and finally obtaining the composite material 3D printing and forming component.
9. The method according to claim 8, wherein: the finite element solving software in the step S1 comprises ANSYS, ABAQUS, MATLAB, COMSOL, icepark, flotherm, microWave Studio, HFSS or Mafia.
10. The method according to claim 8, wherein: the control of the prepreg effect of the printing tows in the step S3 is realized by controlling the heating temperature and the powder spraying amount of the prepreg tows, wherein the heating temperature of the prepreg tows is controlled by regulating the voltage of graphite electrode rollers at two ends of the continuous carbon fiber tows, and the powder outlet amount sprayed by the resin powder spray gun is regulated by regulating the electrostatic nozzle size and the electrostatic voltage of the resin powder spray gun, so that the prepreg effect of different resin matrixes and different resin contents is controlled.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211515463.2A CN116118185A (en) | 2022-11-29 | 2022-11-29 | 3D printing device and method for thermosetting/thermoplastic mixed fiber reinforced composite material |
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| CN202211515463.2A CN116118185A (en) | 2022-11-29 | 2022-11-29 | 3D printing device and method for thermosetting/thermoplastic mixed fiber reinforced composite material |
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