CN116665815A - Method for determining optimal fixed compensation factor in composite material component anti-deformation compensation - Google Patents
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Abstract
The invention provides a method for determining the optimal fixed compensation factor in the process of the inverse deformation compensation of a composite material component, which comprises the steps of deriving three-dimensional coordinates of all nodes before and after the component solidification deformation simulation, selecting different fixed compensation factors to perform inverse deformation calculation on all nodes, simulating again, establishing a functional relation between the different fixed compensation factors and the maximum deformation of the component after the compensation of the different fixed compensation factors, performing curve fitting according to obtained data, taking the compensation factor corresponding to the component deformation as the optimal fixed compensation factor value when the component deformation is 0, repeating the operation to obtain the maximum deformation of the component under the optimal fixed compensation factor, comparing the maximum deformation with the design requirement, adding the data into a data set if the requirement is not met, performing fitting again until the design requirement is met, obtaining the optimal fixed compensation factor if the data is not found for many times, performing secondary or many times of inverse deformation on the basis of a model after the inverse deformation, repeating all the operations until the design requirement is met, and obtaining the optimal fixed compensation factor corresponding to each time of the inverse deformation.
Description
Technical Field
The invention relates to the field of machine manufacturing, in particular to a method for determining an optimal fixed compensation factor in the anti-deformation compensation of a composite material component.
Background
The composite material has the characteristics of high specific modulus, high specific strength, strong designability and the like, so that the composite material is widely used in the fields of aviation, aerospace and the like. However, the composite material member may generate residual stress with complex sources inside during the molding process, which may cause large deformation such as warpage and rebound of the member after demolding.
The conventional methods for reducing the deformation of the composite material component mainly comprise optimizing the layering sequence, optimizing the technological parameters, correcting the mold surface and the like, but the two methods have limited effects on reducing the deformation due to the characteristics of the composite material, and the deformation of the component can be reduced to the greatest extent by combining the methods for correcting the mold surface.
The method of reverse deformation is generally used for correcting the mold surface, namely, the actual measurement or simulation result of the molded component is compared with the design model to obtain the deformation of the lower surface of the component (the lower surface of the component can be considered to be in direct contact with the mold under the condition of not considering auxiliary materials), then the deformation is reversely overlapped on the mold surface, and when the component is molded again, the deformation is counteracted with the previous compensation amount, so that the effect of reducing the deformation can be achieved. Therefore, the magnitude of the compensation amount is critical to reducing the deformation amount of the component, and the compensation amount cannot be accurately guaranteed to exactly offset the deformation amount due to the fact that the deformation amount of the component is related to factors such as structures, materials and the like, so that the ratio of the compensation amount to the deformation amount is defined as a compensation factor and used for measuring the compensation amount.
When the deformation of the component is predicted by using a finite element method, the model is discretized into different nodes, so that the compensation factors of the component can be divided into two types according to whether the compensation factor values of all the nodes are the same or not in the inverse deformation calculation, and one type is that the compensation factors of all the nodes have the same value and are called fixed compensation factors; the other is that all node compensation factors have different values, which is called variable compensation factor. The existing research generally directly takes a compensation factor of 1, and reduces the deformation amount in a continuous iterative compensation mode, and the mode needs more iterative compensation times, so that the compensation efficiency is reduced, and the shape precision of the component is reduced in continuous iterative compensation.
Disclosure of Invention
Technical problem to be solved
In order to reduce the iterative compensation times of the composite material component, improve the compensation efficiency and the shape accuracy of the compensated component, the invention provides a method for determining the optimal fixed compensation factor in the inverse deformation compensation of the composite material component.
Technical proposal
A method for determining an optimal fixed compensation factor in the anti-deformation compensation of a composite material component is characterized by comprising the following steps:
step 1: establishing a finite element model by using finite element software Abaqus, performing curing molding simulation on the composite material component, and respectively deriving three-dimensional coordinates of all nodes before and after the component is deformed;
the method for deriving the node coordinates is that Report-import Field Output of a menu bar is clicked in sequence under a visual analysis module, then the first step and the last step of a simulation process are selected in sequence on a pop-up interface, each time, the deformation type is switched to 'Unique node' and coordinates in three directions are checked, and three-dimensional coordinate files of all nodes before and after deformation of a component can be obtained by clicking an 'OK' button.
Step 2: selecting an initial interval of the fixed compensation factors, and determining a value interval to obtain a plurality of fixed compensation factor values;
the compensation factor is the amount of the reverse compensation amount in the measurement and the reverse deformation calculation, the value is the ratio of the reverse compensation amount of a certain node to the deformation amount of the node, the initial value can be determined by referring to data or according to experience, the value needs to cover an experience interval as much as possible, and the best compensation factor is prevented from being lost. The constant compensation factor means that all nodes of the component use the same compensation factor value.
Step 3: performing inverse deformation calculation on the three-dimensional coordinates of all the nodes by sequentially using each fixed compensation factor to obtain the three-dimensional coordinates of all the nodes compensated by using different fixed compensation factors;
the anti-deformation calculation is that the initial coordinates are subtracted from the coordinates after each node is deformed to obtain the deformation of each node, and the deformation is multiplied by a k and then added to the initial coordinates of each node, so that the node coordinates of each node after the anti-deformation treatment are obtained:
r i ＝o i -k·(d i -o i )
wherein o represents the initial coordinate of the node, namely the coordinate before deformation, d represents the coordinate after deformation of the node, and r represents the coordinate after inverse deformation of the node; k represents a compensation factor, and is the ratio of the compensation quantity to the deformation quantity, and the value is a constant; i represents the node number, the value is [1,2 ], n is the total number of nodes of the component.
Step 4: performing format conversion on the file obtained in the step 3 to obtain a component finite element model subjected to inverse deformation processing by using different fixed compensation factors, repeating the simulation operation of the step 1 to obtain models subjected to re-solidification simulation deformation, repeating the derivation process of the step 1 to obtain three-dimensional coordinate values of all nodes of the models after deformation, and comparing the three-dimensional coordinate values with initial coordinates of all nodes of the component to sequentially obtain the maximum deformation of the component compensated and re-deformed by using different fixed compensation factors;
the method for obtaining the member finite element model is that a notepad is used for opening a file of an inp generated in a curing simulation process of a composite member, a keyword is found, data is deleted, three-dimensional coordinate values of all nodes after reverse deformation are copied and pasted to the place, after the three-dimensional coordinate values are stored, abaqus is opened, an import-model is clicked in sequence, a modified file is selected, and an opening button is clicked, so that the finite element model after reverse deformation can be obtained.
Step 5: and (3) using the plurality of groups of fixed compensation factors obtained in the step (4) and the corresponding maximum deformation value of the component to perform polynomial fitting, so that a curve and a function relation of the fixed compensation factors and the maximum deformation of the component which is deformed again after the primary reverse deformation treatment can be obtained, and calculating to obtain the corresponding value of the fixed compensation factors when the deformation is 0, namely the optimal fixed compensation factors.
Step 6: and (3) repeating the data processing and simulation operations of the step (4) and the step (1) by using the optimal fixed compensation factor obtained in the step (5), so as to obtain the maximum deformation of the component corresponding to the optimal fixed compensation factor, comparing the deformation with the design requirement, if the design requirement is met, indicating that the value is the optimal fixed compensation factor value, otherwise, taking the fixed compensation factor and the deformation as a data set, repeating the operation of the step (5) to obtain a new optimal fixed compensation factor, and repeating the steps to obtain the fixed compensation factor meeting the requirement.
Step 7: if repeated searching is carried out for a plurality of times, the design requirement is not met, and the design requirement can not be met through only one time of reverse deformation treatment, then, based on the model subjected to the one time of reverse deformation treatment, the second time of reverse deformation is carried out, all the steps are repeated, the optimal fixed compensation factor corresponding to the second time of reverse deformation treatment is found, and the repeated operation is carried out for a plurality of times until the design requirement is met, so that the optimal fixed compensation factor corresponding to each time of reverse deformation is obtained;
the secondary reverse deformation is a process of re-giving a new compensation factor to perform reverse deformation based on the model after the primary reverse deformation, thereby reducing the deformation again. Generally, when the primary reverse deformation cannot meet the design requirement, the secondary reverse deformation or even multiple reverse deformation is performed to reduce the deformation amount, thereby finally meeting the design requirement.
The comparison between the step 4 and the initial coordinates refers to the following formula, the three-dimensional coordinates of each node obtained through the inverse deformation calculation are subtracted from the initial three-dimensional coordinates of each node in sequence, and the arithmetic square root of three direction difference values is calculated, so that the deformation of each node can be obtained, wherein the maximum deformation is the maximum deformation of the component. If the deformation amount in a certain direction is only concerned under a specific condition, the maximum deformation amount in a certain direction can be solved in the same way.
Wherein D represents the deformation amount of the node, D represents the coordinate after the node is deformed, o represents the coordinate before the node is deformed, and subscripts x, y and z represent X, Y, Z directions.
The judgment of meeting the design requirement mentioned in the step 6 and the step 7 refers to comparing the maximum deformation of the component in a certain direction or overall situation with the specific design requirement to judge whether the deviation of the component meets the requirement.
The invention has the beneficial effects that: by combining Abaqus simulation software with a polynomial fitting function, a functional relation curve between a fixed compensation factor and the deformation of a component can be obtained, and an optimal fixed compensation factor capable of reducing the deformation to the minimum is found.
Drawings
FIG. 1 is a flow chart of the present invention
FIG. 2 is a finite element model created by taking a plate member as an example of the present invention
FIG. 3 is a view showing the node coordinate interface of the present invention before all nodes of the member are deformed, using a plate member as an example
FIG. 4 is a view showing the node coordinate interface of the present invention after all nodes of the member are deformed, using a plate member as an example
FIG. 5 is a schematic illustration of the replacement of pre-deformation coordinates with post-deformation node coordinates
FIG. 6 is a graph of a fit of different compensation factors and corresponding Z-direction maximum deflection
FIG. 7 is a graph of a data-processed constant compensation factor value and a corresponding Z-direction maximum deflection
FIG. 8 is a graph showing the maximum and average error interfaces in each direction after reverse deformation and re-simulation of the component at a given compensation factor of 1.532
FIG. 9 is a graph of curve fit for finding the best fixed compensation factor
FIG. 10 is a graph showing the maximum and average error interfaces in each direction after reverse deformation and re-simulation of the component when the compensation factor is 1.505
FIG. 11 is a graph showing the maximum and average error interfaces in each direction after reverse deformation and re-simulation of the component when the compensation factor is taken to be 1
Detailed Description
The invention will be further described with reference to the drawings and examples.
The embodiment is implemented on the premise of the technical scheme of the invention, and detailed implementation modes and processes are given. The scope of the invention is not limited to the examples described below.
The method for searching the optimal fixed compensation factor is suitable for components with different shapes, and is exemplified by a flat plate with uniform thickness, and the flow is shown in figure 1:
examples of the steps of the plate member are as follows:
step 1: finite element simulation software Abaqus is used for establishing a finite element model of the plate, as shown in figure 2, and curing molding simulation is carried out on the composite material component, so that three-dimensional coordinates of all nodes before and after deformation of the plate are respectively derived.
The method for deriving the node coordinates is that Report-import Field Output of a menu bar is clicked in sequence under a visual analysis module, then the first step and the last step of a simulation process are selected in sequence on a pop-up interface as shown in fig. 3 and 4, each time, the deformation type is switched to 'Unique node' and coordinates in the three directions are checked, and three-dimensional coordinate files of all nodes before and after deformation of a component can be obtained by clicking an 'OK' button.
Step 2: the probability that the compensation value is in the interval of 1.0-1.5 is larger through experience, in order to avoid losing the optimal compensation factor, the initial interval of the expansion compensation factor is [0.5,2.0], and the values of 0.5, 0.7, 1.0, 1.2, 1.5, 1.6, 1.7 and 2.0 are determined in sequence.
The compensation factor is the amount of the reverse compensation amount in the measurement and the reverse deformation calculation, the value is the ratio of the reverse compensation amount of a certain node to the deformation amount of the node, the initial value can be determined by referring to data or according to experience, the value needs to cover an experience interval as much as possible, and the best fixed compensation factor is avoided being lost. The constant compensation factor means that all nodes of the component use the same compensation factor value.
Step 3: and carrying out inverse deformation calculation on the three-dimensional coordinates of all the nodes by sequentially using each fixed compensation factor, so that the three-dimensional coordinates of all the nodes compensated by using different fixed compensation factors can be obtained.
The inverse deformation calculation is that the deformation of the node is obtained by subtracting the initial coordinates from the coordinates after each node is deformed, and then the deformation is multiplied by a k and then added to the initial coordinates, so as to obtain the inverse deformation, namely the deformed node coordinates:
r i ＝o i -k·(d i -o i )
o represents the initial coordinate of the node, namely the coordinate before deformation, d represents the coordinate after deformation of the node, and r represents the coordinate after inverse deformation of the node; k represents a compensation factor, and is the ratio of the compensation quantity to the deformation quantity, and the value is a constant; i represents the node number, the value is [1,2 ], n is the total number of nodes of the component.
Step 4: and (3) performing format conversion on the file obtained in the step (3) to obtain a flat plate finite element model subjected to inverse deformation processing by using different fixed compensation factors, repeating the simulation operation of the step (1), obtaining a flat plate model subjected to re-solidification simulation deformation, repeating the derivation process of the step (1), obtaining three-dimensional coordinate values of all nodes of the flat plate after deformation, and comparing the three-dimensional coordinate values with initial coordinates of all nodes of the flat plate, so that the maximum deformation of the flat plate after compensation and re-deformation by using different compensation factors can be obtained in sequence.
The method for obtaining the finite element model of the plate is that the notepad is sequentially used for opening the file of the plate and the file of inp is generated in the solidification simulation process of the plate, as shown in figure 5, a keyword Node is found, the data after the keyword Node is deleted, three-dimensional coordinate values of all nodes after reverse deformation are copied and pasted to the place, after the three-dimensional coordinate values are stored, abaqus is opened, the report-model is sequentially clicked, the modified file is selected, and the opening button is clicked, so that the finite element model after reverse deformation can be obtained.
Step 5: the curve and function relation of the maximum deformation of the fixed compensation factors and the plate after one-time reverse deformation can be obtained by using a plurality of groups of fixed compensation factors and the maximum deformation values of the components obtained in the step 4 to perform polynomial fitting, the fitted curve is shown in fig. 6, the fitting effect is influenced by some data points, the fitting is performed after the data is processed, the curve fitting effect is good as shown in fig. 7, and the optimal fixed compensation factor value is 1.532 when the deformation is 0 through calculation.
Step 6: and (3) repeating the data processing and simulation operations mentioned in the step (4) and the step (1) by using the optimal fixed compensation factor obtained in the step (5), wherein as shown in fig. 8, the maximum Z-direction deformation amount of the flat plate piece corresponding to the optimal fixed compensation factor is 2.65723mm (positive and negative indication directions), the result does not meet the requirement, the fixed compensation factor and the deformation amount are taken as data sets, the operation of the step (5) is repeated to obtain a new optimal fixed compensation factor, the new optimal fixed compensation factor is circulated twice, and as shown in fig. 9 and 10, when the final fixed compensation factor is 1.505, the Z-direction deformation amount is 1.71549mm, and the design requirement of the embodiment is that the Z-direction deformation amount is controlled within 2mm, so that the design requirement is finally met.
Step 7: if the design requirement is not met by repeated searching, the design requirement cannot be met by only one time of reverse deformation, then the second time of reverse deformation is carried out based on the model subjected to the first time of reverse deformation, all the steps are repeated, the optimal fixed compensation factor corresponding to the second time of reverse deformation is found, and the reverse deformation is carried out for a plurality of times until the design requirement is met, so that the optimal fixed compensation factor corresponding to each time of reverse deformation is obtained. This example does not require this operation, since the design requirements have been met at step 6.
The Z-direction deformation of the plate piece subjected to the inverse deformation calculation by using the optimal fixed compensation factor obtained by the method is 1.71549mm after the plate piece is reshaped, and the Z-direction deformation of the common method for taking the fixed compensation factor to be 1 is 2.58403mm, as shown in fig. 11, compared with the fixed compensation factor obtained by the method, the deformation of the plate piece is reduced by 33.61%, so that the method for determining the optimal fixed compensation factor provided by the method can be proved to be very effective.
Of course, the above examples are only examples of embodiments of the present invention and are not intended to limit the invention, and many modifications and variations of the present invention will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. A method for determining an optimal fixed compensation factor in the anti-deformation compensation of a composite material component is characterized by comprising the following steps:
step 1: establishing a finite element model by using finite element software Abaqus, performing curing molding simulation on the composite material component, and respectively deriving three-dimensional coordinates of all nodes before and after the component is deformed;
the method for deriving the node coordinates is that Report-import Field Output of a menu bar is clicked in sequence under a visual analysis module, then the first step and the last step of a simulation process are selected in sequence on a pop-up interface, each time, the deformation type is switched to 'Unique node' and coordinates in three directions are checked, and three-dimensional coordinate files of all nodes before and after deformation of a component can be obtained by clicking an 'OK' button.
Step 2: selecting an initial interval of the fixed compensation factors, and determining a value interval to obtain a plurality of fixed compensation factor values;
the compensation factor is the amount of the reverse compensation amount in the measurement and the reverse deformation calculation, the value is the ratio of the reverse compensation amount of a certain node to the deformation amount of the node, the initial value can be determined by referring to data or according to experience, the value needs to cover an experience interval as much as possible, and the best compensation factor is prevented from being lost. The constant compensation factor means that all nodes of the component use the same compensation factor value.
Step 3: performing inverse deformation calculation on the three-dimensional coordinates of all the nodes by sequentially using each fixed compensation factor to obtain the three-dimensional coordinates of all the nodes compensated by using different fixed compensation factors;
the anti-deformation calculation is that the initial coordinates are subtracted from the coordinates after deformation of each node to obtain the deformation of each node, and the deformation is multiplied by a k and then added to the original coordinates of each node, so that the node coordinates of each node after the anti-deformation treatment are obtained:
r i ＝o i -k·(d i -o i )
wherein o represents the initial coordinate of the node, namely the coordinate before deformation, d represents the coordinate after deformation of the node, and r represents the coordinate after inverse deformation of the node; k represents a compensation factor, and is the ratio of the compensation quantity to the deformation quantity, and the value is a constant; i represents the node number, the value is [1,2 ], n is the total number of nodes of the component.
Step 4: performing format conversion on the file obtained in the step 3 to obtain a component finite element model subjected to inverse deformation processing by using different fixed compensation factors, repeating the simulation operation of the step 1 to obtain models subjected to re-solidification simulation deformation, repeating the derivation process of the step 1 to obtain three-dimensional coordinate values of all nodes of the models after deformation, and comparing the three-dimensional coordinate values with initial coordinates of all nodes of the component to sequentially obtain the maximum deformation of the component compensated and re-deformed by using different fixed compensation factors;
the method for obtaining the member finite element model is that a notepad is used for opening a file of an inp generated in a curing simulation process of a composite member, a keyword is found, data is deleted, three-dimensional coordinate values of all nodes after reverse deformation are copied and pasted to the place, after the three-dimensional coordinate values are stored, abaqus is opened, an import-model is clicked in sequence, a modified file is selected, and an opening button is clicked, so that the finite element model after reverse deformation can be obtained.
Step 5: and (3) using the plurality of groups of fixed compensation factors obtained in the step (4) and the corresponding maximum deformation value of the component to perform polynomial fitting, so that a curve and a function relation of the fixed compensation factors and the maximum deformation of the component which is deformed again after the primary reverse deformation treatment can be obtained, and calculating to obtain the corresponding value of the fixed compensation factors when the deformation is 0, namely the optimal fixed compensation factors.
Step 6: and (3) repeating the data processing and simulation operations of the step (4) and the step (1) by using the optimal fixed compensation factor obtained in the step (5), so as to obtain the maximum deformation of the component corresponding to the optimal fixed compensation factor, comparing the deformation with the design requirement, if the design requirement is met, indicating that the value is the optimal fixed compensation factor value, otherwise, taking the fixed compensation factor and the deformation as a data set, repeating the operation of the step (5) to obtain a new optimal fixed compensation factor, and repeating the steps to obtain the fixed compensation factor meeting the requirement.
Step 7: if repeated searching is carried out for a plurality of times, the design requirement is not met, and the design requirement can not be met through only one time of reverse deformation treatment, then, based on the model subjected to the one time of reverse deformation treatment, the second time of reverse deformation is carried out, all the steps are repeated, the optimal fixed compensation factor corresponding to the second time of reverse deformation treatment is found, and the repeated operation is carried out for a plurality of times until the design requirement is met, so that the optimal fixed compensation factor corresponding to each time of reverse deformation is obtained;
the secondary reverse deformation is a process of re-giving a new compensation factor to perform reverse deformation based on the model after the primary reverse deformation, thereby reducing the deformation again. Generally, when the primary reverse deformation cannot meet the design requirement, the secondary reverse deformation or even multiple reverse deformation is performed to reduce the deformation amount, thereby finally meeting the design requirement.
2. The method for determining an optimal compensation factor for compensation of inverse deformations of a composite component according to claim 1, wherein:
the comparison between the step 4 and the initial coordinates refers to the following formula, the three-dimensional coordinates of each node obtained through the inverse deformation calculation are subtracted from the initial three-dimensional coordinates of each node in sequence, and the arithmetic square root of three direction difference values is calculated, so that the deformation of each node can be obtained, wherein the maximum deformation is the maximum deformation of the component. If the deformation amount in a certain direction is only concerned under a specific condition, the maximum deformation amount in a certain direction can be solved in the same way.
Wherein D represents the deformation amount of the node, D represents the coordinate after the node is deformed, o represents the coordinate before the node is deformed, and subscripts x, y and z represent X, Y, Z directions.
3. The method for determining an optimal compensation factor for compensation of inverse deformations of a composite component according to claim 1, wherein:
the judgment of meeting the design requirement mentioned in the step 6 and the step 7 refers to comparing the maximum deformation of the component in a certain direction or overall situation with the specific design requirement to judge whether the deviation of the component meets the requirement.
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