CN117565426A - Manufacturing method and application of carbon fiber and metal composite intelligent structure - Google Patents
Manufacturing method and application of carbon fiber and metal composite intelligent structure Download PDFInfo
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- CN117565426A CN117565426A CN202311623238.5A CN202311623238A CN117565426A CN 117565426 A CN117565426 A CN 117565426A CN 202311623238 A CN202311623238 A CN 202311623238A CN 117565426 A CN117565426 A CN 117565426A
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 125
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 125
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 121
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 41
- 239000002905 metal composite material Substances 0.000 title claims abstract description 17
- 239000011208 reinforced composite material Substances 0.000 claims abstract description 75
- 239000002952 polymeric resin Substances 0.000 claims abstract description 54
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 54
- 239000002131 composite material Substances 0.000 claims abstract description 38
- 229910052751 metal Inorganic materials 0.000 claims abstract description 37
- 239000002184 metal Substances 0.000 claims abstract description 37
- 238000010438 heat treatment Methods 0.000 claims abstract description 25
- 238000012545 processing Methods 0.000 claims abstract description 22
- 239000011248 coating agent Substances 0.000 claims abstract description 20
- 238000000576 coating method Methods 0.000 claims abstract description 20
- 238000011065 in-situ storage Methods 0.000 claims abstract description 18
- 238000005488 sandblasting Methods 0.000 claims abstract description 11
- 238000012544 monitoring process Methods 0.000 claims abstract description 10
- 230000008859 change Effects 0.000 claims abstract description 8
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 55
- 229910052782 aluminium Inorganic materials 0.000 claims description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 22
- 239000011888 foil Substances 0.000 claims description 22
- 230000008569 process Effects 0.000 claims description 19
- 239000000463 material Substances 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 11
- 230000000996 additive effect Effects 0.000 claims description 11
- 238000001816 cooling Methods 0.000 claims description 8
- 238000007731 hot pressing Methods 0.000 claims description 8
- 238000013461 design Methods 0.000 claims description 7
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 6
- 238000005096 rolling process Methods 0.000 claims description 6
- 239000000835 fiber Substances 0.000 claims description 5
- 239000002245 particle Substances 0.000 claims description 5
- 229920006254 polymer film Polymers 0.000 claims description 5
- 230000008054 signal transmission Effects 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 4
- 238000002474 experimental method Methods 0.000 claims description 4
- 238000004804 winding Methods 0.000 claims description 4
- 238000010146 3D printing Methods 0.000 claims description 3
- 239000003963 antioxidant agent Substances 0.000 claims description 3
- 230000003078 antioxidant effect Effects 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 239000007888 film coating Substances 0.000 claims description 2
- 238000009501 film coating Methods 0.000 claims description 2
- 238000002310 reflectometry Methods 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 description 6
- 239000010959 steel Substances 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 239000004696 Poly ether ether ketone Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 229920002530 polyetherether ketone Polymers 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
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- 230000008018 melting Effects 0.000 description 3
- 239000007769 metal material Substances 0.000 description 3
- 238000004321 preservation Methods 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 206010063385 Intellectualisation Diseases 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 238000004093 laser heating Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 229920012287 polyphenylene sulfone Polymers 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 238000007792 addition Methods 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- -1 but not limited to Polymers 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 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
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- 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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/748—Machines or parts thereof not otherwise provided for
- B29L2031/75—Shafts
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Health & Medical Sciences (AREA)
- Electromagnetism (AREA)
- Toxicology (AREA)
- Moulding By Coating Moulds (AREA)
- Laminated Bodies (AREA)
Abstract
The invention discloses a manufacturing method and application of a carbon fiber and metal composite intelligent structure, comprising the following steps: designing and manufacturing a metal core mould, carrying out sand blasting treatment on a processing area on the core mould, and then coating a high polymer resin film; fixing a core mould wrapped by a high polymer resin film on a rotary platform; moving laser focusing auxiliary heating in-situ forming equipment to the vicinity of a core mold, and pressing the continuous carbon fiber reinforced composite material on the surface of the core mold at the initial position of a first layer path by using a roller; operating the mechanical arm and the rotating platform according to a set speed, and enabling the continuous carbon fiber reinforced composite material to sequentially finish each layer of continuous carbon fiber reinforced composite material according to a set path to obtain a carbon fiber and metal intelligent composite structure; and connecting the carbon fiber area with an electrode and a resistance meter, and realizing self-monitoring of internal temperature stress according to the resistance change of the carbon fiber. The invention can realize the effective connection of the carbon fiber reinforced composite material and the metal, improve the bonding strength of a heterogeneous interface and reduce the thermal deformation of the composite member.
Description
Technical Field
The invention relates to the field of fiber composite reinforcement manufacturing, in particular to a manufacturing method and application of a carbon fiber and metal composite intelligent structure.
Background
The light weight is a trend of industrial equipment development, and the demand for light weight and high strength intelligent structures in various fields of vehicles, aerospace, machine tool manufacturing and the like is also increasing, so that the light weight intelligent components realized by utilizing the excellent performance of the new materials have great research potential. Among the new materials, carbon fiber reinforced composite materials are widely used in engineering due to the advantages of high strength, high specific stiffness, excellent oxidation resistance, vibration resistance, fatigue resistance, excellent axial heat conduction performance, low thermal expansion coefficient and the like, and good effects are obtained. It is worth mentioning that the self-monitoring of the component can be realized by utilizing the force resistance characteristic of the carbon fiber reinforced composite material.
However, carbon fiber reinforced composites do not completely replace metallic materials. The main reason is that although carbon fiber reinforced composite materials have some excellent properties, the anisotropy of the carbon fiber reinforced composite materials determines that the metal materials are still indispensable in terms of comprehensive properties, impact resistance and the like. The carbon fiber reinforced composite material and the metal composite intelligent member are expected to have excellent thermal stability while realizing higher mechanical properties, and play an important role under extreme conditions in the fields of space, vehicles and the like. However, the strength of the interface greatly constrains the performance of the composite structure for excellent performance. How to prepare a high-strength intelligent structure with excellent comprehensive performance by utilizing a carbon fiber reinforced composite material and a metal material together becomes a scientific research subject which is attracting attention.
The physicochemical properties of carbon fiber reinforced composites and metals are quite different. Therefore, it is difficult to connect the carbon fiber reinforced composite material and the metal by the existing welding method. At present, the bonding of carbon fiber reinforced composite materials and metals is generally performed by mechanical bonding such as adhesive bonding, bolting, self-piercing riveting, and the like. However, these bonding methods have many inherent problems. For example, chinese patent publication No. CN101524903a discloses a fiber metal laminate, in which a carbon fiber composite layer bonded to two adjacent metal plates is laid between the two adjacent metal plates. Chinese patent publication No. CN105523052a discloses a carbon fiber skin structure, the carbon fiber skin is provided with an embedded portion, and the embedded portion is embedded in the metal base body and fixes the carbon fiber skin and the metal base body into a whole by bolts.
In recent years, many innovative joining techniques such as friction spot welding, resistance welding with an interposed conductive element, ultrasonic welding, and laser joining have been studied. Laser bonding has the advantages of non-contact processing and high efficiency compared to other welding techniques. The carbon fiber reinforced composite material and the metal are researched by the scholars through the laser connection process, but the researched technology generally adopts a thin metal plate, and most of the thin metal plate is directly connected, the performance of a bonding interface is improved through the regulation and control of process parameters, and no report on improving the interface bonding performance through coating a transition layer exists. In addition, no related research has been carried out on a metal-carbon fiber reinforced composite material mixed structure containing complex bonding surfaces such as cambered surfaces.
Disclosure of Invention
The invention provides a manufacturing method and application of a carbon fiber and metal composite intelligent structure, which can realize effective connection of a carbon fiber reinforced composite material and metal, improve the interface shear strength and reduce the thermal deformation, and realize the weight reduction and the intellectualization of the composite structure.
A manufacturing method of a carbon fiber and metal composite intelligent structure comprises the following steps:
(1) Designing and manufacturing a metal mandrel, adopting sand blasting to a carbon fiber design processing area on the mandrel, and then coating a high polymer resin film on the surface of the area;
(2) Generating a continuous carbon fiber reinforced composite material additive manufacturing path on the mandrel; setting output parameters of a laser, the moving speed of a mechanical arm and the rotating angular speed of a rotating platform;
(3) Fixing a core mould wrapped by a high polymer resin film on a rotary platform;
(4) Adjusting the pose of a mechanical arm, moving laser focusing auxiliary heating in-situ forming equipment to the vicinity of a core mold, and pressing the continuous carbon fiber reinforced composite material on the surface of the core mold at the initial position of a first layer path by a roller of the laser focusing auxiliary heating in-situ forming equipment;
(5) Opening a laser, and operating the mechanical arm and the rotating platform according to a set speed to enable the continuous carbon fiber reinforced composite material to move according to a set path; after the first layer of continuous carbon fiber reinforced composite material is laid, the laser is turned off, and the continuous carbon fiber reinforced composite material is cut off;
(6) After the temperature of the first layer of continuous carbon fiber reinforced composite material is reduced to room temperature, the mechanical arm and the rotary platform sequentially move according to a set material adding path, and the continuous carbon fiber reinforced composite material adding manufacturing is carried out by matching with the opening and closing of a laser; after all manufacturing processes are completed in the design processing area, the mechanical arm and the rotating platform stop moving, and the laser is closed, so that the composite intelligent structure is obtained.
Further, in the step (1), the metal core mold may be manufactured by a subtractive method; or, a metal core mold containing an internal complex structure is manufactured through a metal 3D printing process, and then the overall strength is improved through compounding with carbon fibers.
In the step (1), the polymer resin film coating method adopts a direct laying method or a hot pressing method.
The specific process of the direct laying method is as follows: cutting a high polymer resin film into a certain width and winding, then installing a wound high polymer film belt on laser focusing auxiliary heating in-situ forming equipment, and driving the laser focusing auxiliary heating in-situ forming equipment to coat in a processing area after sand blasting by using a mechanical arm according to a set path.
The hot pressing method comprises the following specific processes: coating a high polymer resin film on the processed area after sand blasting, wrapping an aluminum foil, and putting the aluminum foil into a die matched with a metal core die; heating and pressurizing the die for a period of time by using a hot press, and then cooling; taking out the core mould and tearing off the aluminum foil.
Coating a high polymer resin film and then wrapping an aluminum foil, wherein the specific process is as follows:
before coating the polymer resin film, cleaning the core mold and the polymer resin film by using acetone to remove greasy dirt and tiny particles, and then drying;
then, coating an antioxidant paint on the area outside the processing area on the core mold, and then heating the core mold to 500 ℃ and cooling to improve the core mold absorptivity of the core mold to laser energy in the laying process of the first layer of continuous carbon fiber reinforced composite material;
and coating a high polymer resin film in a processing area by adopting a proper method, ensuring that the high polymer resin film is uniformly wrapped on the surface of a core mold, avoiding overlapping and wrinkling, and then wrapping an aluminum foil with the thickness of 0.3-1 mm.
In the step (1), the polymer resin film adopts a matrix resin material in the continuous carbon fiber reinforced composite material or adopts other thermoplastic resins including polyether ether ketone, nylon polyphenylene sulfone, polyamide and polycarbonate.
In the step (2), an included angle formed by the moving speed of the mechanical arm and the rotating linear speed of the rolling point on the mandrel is the same as the included angle between the fiber direction of the continuous carbon fiber reinforced composite material and the axis of the mandrel.
In the step (2), the set output parameters of the laser are specifically: a fixed power output mode is selected when the first layer of continuous carbon fiber reinforced composite material is manufactured, and the rest layer adopts a fixed temperature output mode, so that the stability of the processing temperature is ensured; the output power and the temperature are determined together according to the high polymer resin material, the laser irradiation angle, the core mold surface absorptivity and the reflectivity, so that the temperature difference between the processed surface and the surface of the continuous carbon fiber reinforced composite material is ensured to be less than 50 ℃.
In the step (4), when the first layer of continuous carbon fiber reinforced composite material is manufactured, the area of a laser spot irradiated on the high polymer resin film is not lower than 2/3 of the total area of the laser spot; when the continuous carbon fiber reinforced composite material is manufactured in the follow-up process, the coincidence of the laser center and the initial rolling point on the roller is ensured, and the light spot areas on the surfaces of the continuous carbon fiber reinforced composite material and the manufactured continuous carbon fiber reinforced composite material are equal.
The application of the carbon fiber and metal composite intelligent structure utilizes the manufacturing method to manufacture the composite intelligent spindle for the machine tool spindle, realizes the self-monitoring function of the spindle, and comprises the following self-monitoring process:
assembling the composite intelligent main shaft on a matched machine tool, wherein two ends of a continuous carbon fiber reinforced composite material on the composite intelligent main shaft are signal transmission areas; the signal transmission area is ensured to be contacted with the annular signal acquisition brush when the main shaft works, and the acquired resistance change condition is transmitted into a computer through the signal acquisition brush and recorded; and the relation of temperature and carbon fiber resistance change obtained by the comparison experiment reflects the temperature condition inside the carbon fiber layer when the composite intelligent main shaft works, so that the self-monitoring of the composite intelligent main shaft is realized.
Compared with the prior art, the invention has the following beneficial effects:
the invention realizes the manufacture of the metal core mould by using the traditional material reduction method or the novel 3D printing method, coats a high polymer film on the surface of the metal core mould, and then realizes the in-situ additive manufacturing of the carbon fiber reinforced composite material by using the fusion laser focusing heating in-situ curing automatic wire laying technology. The method of the invention realizes the effective connection of the carbon fiber reinforced composite material and metal, improves the interfacial shear strength by 60% compared with the traditional laser direct connection technology, reduces the axial thermal deformation of the composite shaft by 12.6% compared with the pure metal shaft (45 # steel, PEEK and CF/PEEK are adopted in experiments), and realizes the light weight and the intellectualization of the composite intelligent structure.
Drawings
FIG. 1 is a flow chart of a method for manufacturing a carbon fiber and metal composite intelligent structure according to the present invention;
FIG. 2 is a schematic diagram of a mold mated with a steel mandrel in an embodiment of the present invention;
FIG. 3 is a schematic diagram of a robot-assisted laser focusing-based continuous carbon fiber reinforced composite in-situ additive manufacturing platform employed in an embodiment of the present invention;
FIG. 4 is a schematic diagram of a composite intelligent spindle prepared according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a composite intelligent spindle and signal acquisition device in an embodiment of the present invention;
FIG. 6 is a graph showing the comparison of the axial thermal deformations of a composite intelligent spindle and a pure metal spindle obtained according to an embodiment of the present invention.
Detailed Description
The invention will be described in further detail with reference to the drawings and examples, it being noted that the examples described below are intended to facilitate the understanding of the invention and are not intended to limit the invention in any way.
As shown in fig. 1, a method for manufacturing a carbon fiber and metal composite intelligent structure comprises the following steps:
s01, designing and manufacturing a metal core mold; the carbon fiber design processing area on the mandrel is subjected to sand blasting treatment, and then a high polymer resin film is coated on the surface of the area.
The sand blasting should be as uniform as possible, so that the air pressure and the distance between the spray gun and the surface of the core mould are kept unchanged during operation. The particle size of the sand is recommended to be 0.425mm (40 mesh) in diameter, and the better the wettability of the polymer resin with the metal is, the smaller the particle size should be.
The polymer resin may be a matrix resin material in a continuous carbon fiber reinforced composite material, or may be other thermoplastic resins including, but not limited to, polyetheretherketone, nylon polyphenylene sulfone, polyamide, polycarbonate, and the like.
The polymer resin film can be coated on the surface of the processing area by adopting a direct laying method or a hot pressing method.
The specific process of the direct laying method is as follows: cutting a high polymer resin film into a certain width and winding, then mounting the wound high polymer film belt on laser focusing auxiliary heating in-situ forming equipment, and driving the laser focusing auxiliary heating in-situ forming equipment to coat in a processing area after sand blasting treatment by using a mechanical arm according to a set path;
the hot pressing method comprises the following specific processes: coating a high polymer resin film on the processed area after sand blasting, wrapping an aluminum foil, and putting the aluminum foil into a die matched with a metal core die; heating and pressurizing the die for a period of time by using a hot press, and then cooling; taking out the mandrel and tearing off the aluminum foil.
Coating a high polymer resin film and then wrapping an aluminum foil, wherein the specific process is as follows:
before coating the polymer resin film, cleaning the core mold and the polymer resin film by using acetone to remove greasy dirt and tiny particles, and then drying;
then, an antioxidant coating is coated on the area outside the processing area on the mandrel, and then the mandrel is heated to 500 ℃ and then cooled so as to improve the absorptivity of the mandrel to laser energy in the laying process of the first layer of continuous carbon fiber reinforced composite material; heating means include, but are not limited to, the use of high temperature ovens and lasers.
And coating a high polymer resin film on the processing area to ensure that the high polymer resin film is uniformly wrapped on the surface of the core mold without overlapping and wrinkling, and then wrapping an aluminum foil with the thickness of 0.3-1 mm.
And a release agent can be uniformly sprayed between the aluminum foil and the high polymer resin film, so that the aluminum foil can be separated after hot pressing. If the width of the composite area exceeds the widths of the aluminum foil and the high polymer resin film, the composite area is wrapped in a spiral winding mode along the axis of the core mold, so that a multi-end splicing mode is avoided.
The heating temperature of the hot press should exceed the melting point of the polymer resin by more than 10 ℃, and the recommended pressure is 0.7-1MPa. After the hot press heats the die to the set temperature, the heat preservation time should not be less than 5 minutes. The high molecular resin with high melting point and high viscosity should be suitable for prolonging the heat preservation time.
The procedure should be set, the mould is cooled in the hot press in a heat preservation and pressure maintaining mode, the cooling time is prolonged as far as possible, the temperature is reduced to below the crystallization transition end temperature of the polymer resin, and then the polymer resin is taken out for air cooling to the room temperature. Meanwhile, the surface of the core mold is covered by non-carbon fiber, and rust prevention and thermal deformation prevention measures are adopted.
S02, generating a continuous carbon fiber reinforced composite material additive manufacturing path on the mandrel; setting laser output parameters, a mechanical arm moving speed and a rotating angle speed of a rotating platform.
The included angle formed by the moving speed of the mechanical arm and the rotating linear speed at the rolling point of the mandrel is the same as the included angle formed by the fiber direction of the continuous carbon fiber reinforced composite material and the axis of the mandrel.
For the arrangement of different layers of carbon fibers, reference should be made to the law of mixing, ensuring overall rigidity while possessing a small coefficient of thermal expansion.
Alternatively, instead of a laser, a heat gun, a hot gas torch, or the like may be used.
The laser output should be selected to have a fixed power output mode when the first layer of continuous carbon fiber reinforced composite is manufactured. The rest recommended adopts a fixed temperature output mode, so that the processing temperature is ensured to be stable. The output power and the temperature are determined together according to the high polymer resin material, the laser irradiation angle, the core mold surface absorptivity and emissivity, so that the temperature difference between the processed surface and the surface of the continuous carbon fiber reinforced composite material is ensured to be less than 50 ℃.
S03, fixing the core mould uniformly wrapped by the polymer resin on a rotary platform.
If the high polymer resin film is coated by adopting a hot pressing method, the core mould is taken out after the coating is finished, the aluminum foil is torn off, and the core mould uniformly wrapped by the high polymer resin is fixed on the rotary platform by utilizing the three-jaw chuck and the ejector pin.
S04, moving the laser focusing auxiliary heating in-situ forming equipment to the vicinity of the core mold, and driving the roller to press the continuous carbon fiber reinforced composite material on the surface of the core mold at the initial position of the first layer path by the cylinder.
When the first layer of continuous carbon fiber reinforced composite material is manufactured, the laser spot area irradiated on the polymer film should be not lower than 2/3 of the total area. When the continuous carbon fiber reinforced composite material is manufactured in the follow-up process, the coincidence of the laser center and the initial rolling point on the roller is ensured, and the light spot areas on the surfaces of the continuous carbon fiber reinforced composite material and the manufactured continuous carbon fiber reinforced composite material are equal.
S05, opening the laser, operating the mechanical arm and the rotating platform according to a set speed, enabling the continuous carbon fiber reinforced composite material to move according to a set path, and sequentially completing each layer of continuous carbon fiber reinforced composite material to obtain the intelligent composite structure of the carbon fiber and the metal.
And the roller is utilized to compress the melted high polymer resin and the carbon fiber on the surface of the core mold together after laser heating, so that the carbon fiber reinforced composite material is effectively connected with the core mold. After the first layer of continuous carbon fiber reinforced composite material is laid, the laser is turned off, and the continuous carbon fiber reinforced composite material is cut off.
After the temperature of the first layer of continuous carbon fiber reinforced composite material is reduced to room temperature, the mechanical arm and the rotary platform sequentially move according to a set material adding path, and the continuous carbon fiber reinforced composite material adding manufacturing is carried out by matching with the opening and closing of a laser. After the design processing area finishes all manufacturing processes, the mechanical arm and the platform stop moving, and the laser is closed, so that the composite intelligent structure is obtained.
And S06, connecting the carbon fiber area with an electrode and a resistance meter, and realizing self-monitoring of internal temperature stress according to resistance change.
In the following, this embodiment takes a carbon fiber and steel composite intelligent spindle as an example, and describes a manufacturing method and application thereof.
A steel mandrel is designed, and the steel mandrel can be matched with other parts for use through threads and bearings on the outer surface. In order to enlarge the heat dissipation area and enhance the cooling effect, a fractal structure can be designed in the shaft. After the design of the mandrel 5 is completed, a layer of polymer resin film 6 and an aluminum foil 7 with the thickness of 0.3 mm are sequentially wrapped at the position where the outer surface is connected with the carbon fiber, and then the polymer resin film and the aluminum foil are put into a custom mold 8 together, as shown in fig. 2.
And (3) placing the die into a flat plate hot press, heating to a temperature above the melting point of the high polymer resin, preserving heat, cooling to room temperature, and tearing off the aluminum foil to obtain the metal core shaft uniformly covered by the high polymer resin.
The invention adopts a continuous carbon fiber reinforced composite material in-situ additive manufacturing platform based on robot-assisted laser focusing heating, as shown in fig. 3, and comprises a control cabinet 1, a mechanical arm 2, laser focusing-assisted heating in-situ forming equipment 3 arranged at the tail end of the mechanical arm 2, and a rotary platform 4 for placing a steel mandrel 5.
The mandrel 5 is moved to a heatable rotating platform 4 and is fixed by a three-jaw chuck, the pose of the mechanical arm 2 is adjusted, the laser focusing auxiliary heating in-situ forming equipment 3 is moved to the vicinity of the mandrel 5, and the cylinder drives the roller to press the continuous carbon fiber reinforced composite material on the surface of the mandrel 5 at the starting point of the additive manufacturing path. And simultaneously operating the mechanical arm 2 and the rotary platform 4 according to set parameters, and pressing the melted high polymer resin and the carbon fiber on the surface of the mandrel by using the roller after laser heating, so that the carbon fiber reinforced composite material is effectively connected with the mandrel. And cutting and re-conveying the continuous carbon fiber reinforced composite material by laser focusing auxiliary heating additive manufacturing equipment after finishing the processing thickness of each layer of carbon fiber reinforced composite material. After the mandrel and the processed carbon fibers are cooled to room temperature, adjusting the laser temperature, the mechanical arm and the mandrel movement speed, moving the laser focusing auxiliary heating additive manufacturing equipment to the starting point of the second layer carbon fiber additive path, and pressing the continuous carbon fiber reinforced composite material on the surface of the first layer carbon fiber by the roller. And finishing the additive manufacturing between the same materials of the subsequent continuous carbon fiber reinforced composite material according to the path.
As shown in fig. 4, the composite intelligent spindle after all manufacturing is provided with connecting threads 9 and bearing joints 10 at two ends of a mandrel 5, and signal transmission areas 12 are arranged at two ends of a continuous carbon fiber reinforced composite material 11.
The composite smart spindle may be assembled and connected as shown in fig. 5. The power line 13 provides voltage, the carbon fiber layer at a specific position is loaded through the signal acquisition brush 14, meanwhile, the acquired resistance change condition is fed back to the computer 17 through the data line 16 through the signal acquisition ring 15 and recorded, the relation of temperature and carbon fiber resistance change obtained through comparison experiments reflects the temperature condition inside the carbon fiber layer when the composite shaft works, and the self-monitoring of the composite main shaft is realized.
The invention explores a method for improving the bonding performance of a metal and carbon fiber composite material by a method of coating a high polymer resin film. As shown in FIG. 6, the axial thermal deformation of the composite intelligent spindle obtained by the embodiment of the invention is reduced by 12.6% compared with that of a pure metal spindle, and a good technical effect is obtained.
The foregoing embodiments have described in detail the technical solution and the advantages of the present invention, it should be understood that the foregoing embodiments are merely illustrative of the present invention and are not intended to limit the invention, and any modifications, additions and equivalents made within the scope of the principles of the present invention should be included in the scope of the invention.
Claims (8)
1. The manufacturing method of the carbon fiber and metal composite intelligent structure is characterized by comprising the following steps of:
(1) Designing and manufacturing a metal mandrel, adopting sand blasting to a carbon fiber design processing area on the mandrel, and then coating a high polymer resin film on the surface of the area;
(2) Generating a continuous carbon fiber reinforced composite material additive manufacturing path on the mandrel; setting output parameters of a laser, the moving speed of a mechanical arm and the rotating angular speed of a rotating platform;
(3) Fixing a core mould wrapped by a high polymer resin film on a rotary platform;
(4) Adjusting the pose of a mechanical arm, moving laser focusing auxiliary heating in-situ forming equipment to the vicinity of a core mold, and pressing the continuous carbon fiber reinforced composite material on the surface of the core mold at the initial position of a first layer path by a roller of the laser focusing auxiliary heating in-situ forming equipment;
(5) Opening a laser, and operating the mechanical arm and the rotating platform according to a set speed to enable the continuous carbon fiber reinforced composite material to move according to a set path; after the first layer of continuous carbon fiber reinforced composite material is laid, the laser is turned off, and the continuous carbon fiber reinforced composite material is cut off;
(6) After the temperature of the first layer of continuous carbon fiber reinforced composite material is reduced to room temperature, the mechanical arm and the rotary platform sequentially move according to a set material adding path, and the continuous carbon fiber reinforced composite material adding manufacturing is carried out by matching with the opening and closing of a laser; after all manufacturing processes are completed in the design processing area, the mechanical arm and the rotating platform stop moving, and the laser is closed, so that the composite intelligent structure is obtained.
2. The method of manufacturing a carbon fiber and metal composite intelligent structure according to claim 1, wherein in the step (1), the metal core mold is manufactured by a subtractive method, or the metal core mold including the internal complex structure is manufactured by a metal 3D printing process.
3. The method for manufacturing a carbon fiber and metal composite intelligent structure according to claim 1, wherein in the step (1), a polymer resin film coating method adopts a direct laying method or a hot pressing method;
the specific process of the direct laying method is as follows: cutting a high polymer resin film into a certain width and winding, then mounting the wound high polymer film belt on laser focusing auxiliary heating in-situ forming equipment, and driving the laser focusing auxiliary heating in-situ forming equipment to coat in a processing area after sand blasting treatment by using a mechanical arm according to a set path;
the hot pressing method comprises the following specific processes: coating a high polymer resin film on the processed area after sand blasting, wrapping an aluminum foil, and putting the aluminum foil into a die matched with a metal core die; heating and pressurizing the die for a period of time by using a hot press, and then cooling; taking out the core mould and tearing off the aluminum foil.
4. The method for manufacturing the carbon fiber and metal composite intelligent structure according to claim 3, wherein the aluminum foil is coated after the high polymer resin film is coated, and the specific process is as follows:
before coating the polymer resin film, cleaning the core mold and the polymer resin film by using acetone to remove greasy dirt and tiny particles, and then drying;
then, an antioxidant coating is coated on the area outside the processing area on the mandrel, and then the mandrel is heated to 500 ℃ and then cooled so as to improve the absorptivity of the mandrel to laser energy in the laying process of the first layer of continuous carbon fiber reinforced composite material;
and coating a high polymer resin film on the processing area to ensure that the high polymer resin film is uniformly wrapped on the surface of the core mold without overlapping and wrinkling, and then wrapping an aluminum foil with the thickness of 0.3-1 mm.
5. The method according to claim 1, wherein in the step (2), an included angle formed by a moving speed of the mechanical arm and a rotating linear speed at a rolling point on the mandrel is the same as an included angle formed by a fiber direction of the continuous carbon fiber reinforced composite material layer and an axis of the mandrel.
6. The method for manufacturing a carbon fiber and metal composite intelligent structure according to claim 1, wherein in the step (2), the set laser output parameters are specifically: a fixed power output mode is selected when the first layer of continuous carbon fiber reinforced composite material is manufactured, and the rest layer adopts a fixed temperature output mode, so that the stability of the processing temperature is ensured; the output power and the temperature are determined together according to the high polymer resin material, the laser irradiation angle, the core mold surface absorptivity and the reflectivity, so that the temperature difference between the processed surface and the surface of the continuous carbon fiber reinforced composite material is ensured to be less than 50 ℃.
7. The method for manufacturing a carbon fiber and metal composite intelligent structure according to claim 1, wherein in the step (4), when the first layer of continuous carbon fiber reinforced composite material is manufactured, the area of the laser spot irradiated on the polymer resin film is not lower than 2/3 of the total area of the laser spot; when the continuous carbon fiber reinforced composite material is manufactured in the follow-up process, the coincidence of the laser center and the initial rolling point on the roller is ensured, and the light spot areas on the surfaces of the continuous carbon fiber reinforced composite material and the manufactured continuous carbon fiber reinforced composite material are equal.
8. The application of the carbon fiber and metal composite intelligent structure is characterized in that the composite intelligent main shaft manufactured by the method of any one of claims 1 to 7 is used for a main shaft of a machine tool, the main shaft self-monitoring function is realized, and the self-monitoring process is as follows:
assembling the composite intelligent main shaft on a matched machine tool, wherein two ends of a continuous carbon fiber reinforced composite material on the composite intelligent main shaft are signal transmission areas; the signal transmission area is ensured to be contacted with the annular signal acquisition brush when the main shaft works, and the acquired resistance change condition is transmitted into a computer through the signal acquisition brush and recorded; and the relation of temperature and carbon fiber resistance change obtained by the comparison experiment reflects the temperature condition inside the carbon fiber layer when the composite intelligent main shaft works, so that the self-monitoring of the composite intelligent main shaft is realized.
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