CN117708905A - Automatic laying track design method for composite material shell structure - Google Patents
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- 238000011056 performance test Methods 0.000 claims abstract description 3
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- 238000011065 in-situ storage Methods 0.000 description 8
- 238000007493 shaping process Methods 0.000 description 8
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Abstract
The invention belongs to the field of composite material forming technology, which comprises the following steps: the method comprises the following steps: step 1, performing a prepreg plane laying performance test, and determining a minimum radius Rmin of a prepreg plane laid without folds; step 2, calculating curved surface parameters of the shell structure, and obtaining curved surface parameters, geodesic curvature (Kg) and Gaussian curvature (K) required by a laying track design method; step 3, carrying out the calculation of a laying track without folds and gaps on the surface of the shell structure; and 4, carrying out shell structure envelope analysis based on the fold-free and gap-free defect laying track on the shell surface and the parameter information of the curved surface of the revolving body, and uniformly distributing the prepreg on the surface of the shell structure. According to the invention, the design method can be used for effectively developing the laying track design of the shell structure without folds and gaps and completely enveloping, so that the efficiency of planning the laying track of the composite shell is improved, and the waste of expensive prepreg is reduced.
Description
Technical Field
The invention belongs to the field of composite material forming processes, and particularly relates to a method for designing an automatic laying track of a composite material shell structure.
Background
The pressure vessel prepared from the composite material is an important storage device, has the advantages of light weight, high strength, good fatigue resistance, good corrosion resistance and the like, and is particularly suitable for aerospace, military application and parts of the space above water. In order to improve the damage strength of the pressure container, the laid fibers need to be arranged in a variable angle, an automatic laying process for fixing the laying position of the prepreg without depending on tension is matched with the movement of a robot, so that the designability of the laying track of the prepreg is stronger, the precision is higher, the defect handling controllability is strong, meanwhile, the real-time prepreg curing technology can effectively improve the product forming rate, secondary curing and forming are not dependent on other equipment, and the production period of the product is reduced while the equipment investment is saved; the method has the advantages that the automatic laying process is enabled to be the development direction of shell structure preparation, laying track planning is one of the most important processes for preparing the shell structure by the automatic laying process, the process comprises path generation, path evaluation and motion simulation, and the reasonable laying track can effectively inhibit fold defects in the prepreg forming process, so that defect accumulation is avoided, and the mechanical property of the shell structure is reduced.
Lay-up trajectory design is an important piece of material in the composite component manufacturing process. According to the specified laying technological parameters, the prepreg is formed on the surface of a die in situ according to a planned path under the action of a press roller mechanism, and certain bonding strength is required to be ensured between layers; however, due to limitations of molding technology and prepreg molding characteristics, it may not be possible to lay down a lay-down trajectory that meets design requirements; in practical engineering application, laying path planning is usually carried out firstly, and then the suitability of a laying track is evaluated according to prepreg forming conditions; the rationality of the laying trajectory of the shell structure determines to a great extent that the product quality of the shell composite member is affected by many factors such as the geometric characteristics of the curved surface, the deformation characteristics of the prepreg, the deformation characteristics of the press roller, and the like, and any unreasonable influencing factors may cause local laying path modification or overall laying path modification, thereby reducing the efficiency of planning the laying trajectory of the shell and wasting expensive prepreg.
Disclosure of Invention
In order to solve the problems, the invention provides a method for designing an automatic laying track of a composite shell structure.
A design method for an automatic laying track of a composite shell structure comprises the following steps:
step 1, performing a prepreg plane laying performance test to determine a minimum radius R of a prepreg plane laid without folds min ；
Step 2, calculating the curved surface parameters of the shell structure, obtaining the curved surface parameters required by the laying track design method, and measuring the ground curvature (K) g ) Gaussian curvature (K);
step 3, carrying out the calculation of a laying track without folds and gaps on the surface of the shell structure;
and 4, carrying out shell structure envelope analysis based on the fold-free and gap-free defect laying track on the shell surface and the parameter information of the curved surface of the revolving body, and uniformly distributing the prepreg on the surface of the shell structure.
Preferably, in step 2, the shell structure is an unequal hole shell structure, the forming track without the fold defect is divided into a seal head area and a barrel area, and the barrel area is divided into three areas.
In summary, the present invention includes at least one of the following beneficial technical effects: according to the invention, the design method can be used for effectively developing the laying track design of the shell structure without folds and gaps and completely enveloping, so that the efficiency of planning the laying track of the composite shell is improved, and the waste of expensive prepreg is reduced.
Drawings
FIG. 1 is a schematic view of a housing structure;
FIG. 2 is a schematic diagram of the change of the track forming angle of the seal head area;
FIG. 3 is a schematic view of the variation of the trajectory shaping angle of the barrel section area;
FIG. 4 is a schematic view of the angle of the molding of the head section prepreg;
FIG. 5 is a schematic view of a prepreg curved surface forming angle;
FIG. 6 is a prepreg envelope analysis flow chart;
FIG. 7 is a schematic illustration of dimensional parameters of a pre-preg as molded shell;
FIG. 8 is a schematic view of the variation range of the molding angle of the head segment;
FIG. 9 is a graph of the effect of different complete molded turn shells;
FIG. 10 is a graph of the effect of unequal hole prepreg molding;
FIG. 11 is a graph of the calculation and analysis of the initial molding angle trace strain of the closure head;
fig. 12 is a graph showing the effect of defect-free track formation of the shell head.
Detailed Description
As shown in fig. 1-12, a method for designing an automatic laying track of a composite shell structure includes:
1. main algorithm for calculating forming track of shell without fold defect
The shaping track design without fold defect is divided into a head region design and a barrel region design, the barrel section is divided into three regions (I, II and III regions), the I region and the III region are shaping angle transition regions, and the shaping angle of the shaping track in the region is changed; the zone II is a constant zone of the forming angle of the barrel section, and the three zones correspond to the axial lengths L1, L2 and L3 and the initial (alpha) 0 ) And the end forming angle (alpha) is related to the minimum forming radius (Rmax) of the planar forming of the prepreg without wrinkling defects;
parameters which need to be input are size parameters of a core mold, an initial molding angle of a seal head end, the width of a prepreg and the minimum molding radius of a plane molding non-wrinkling defect, wherein after calculation, the parameters which need to be input are selected to be provided with an end molding angle of the seal head end, initial and final winding angles of a barrel section I and a barrel section III and a barrel section II;
(1) Method for calculating end socket end forming track
When the laser in-situ forming technology is utilized to design the curved surface in-situ forming track of the prepreg, the maximum strain condition of the prepreg is needed to be considered in order to avoid the occurrence of the wrinkle defect. Geodesic curvature (K) of prepreg curved surface forming strain and track trajectory g ) The specific expressions relating to the gaussian curvature (K) and the prepreg width (W) are as follows:
wherein R is min : minimum forming radius when the prepreg plane forming does not have wrinkling defect;
ε max : forming the maximum strain of the curved surface of the prepreg;
based on differential geometry knowledge, the first derivative of the curved geodesic curvature K_g, the curved Gaussian curvature K, and the axial length z with respect to the arc length s on a surface of a revolution of a body can be expressed as follows:
in the method, in the process of the invention,a first derivative of the shaping angle (α) with respect to the arc(s);
a first derivative of the axial length (z) with respect to radian(s);
r: a shell radius;
r': first derivative of shell radius to axial length.
r': second derivative of shell radius versus axial length.
The first derivative expression of the lower head section track forming angle (alpha) to the axial length (z) can be obtained by deducting from the formulas (1), (2), (3) and (4), and the following expression can be solved by using a numerical method and an analytic method. Due to R min Expressed is the minimum forming radius of the prepreg planar forming, so when R min When the numerical value is expanded, the track forming angle (alpha) solved by the formula (5) and the formula (6) still meets the requirement of no-fold defect, and finally, the end socket segment forming track forming angle is solved to be in two ranges.
As shown in figure 2, R is min The initial molding angle is 60 ° for the head trace molding angle change schematic diagram, the blue and red areas are the prepreg molding angle selectable ranges for given head dimensions and prepreg dimensions and performance conditions, the end molding angle selectable ranges are 4.195 ° to 14.86 ° and 18.39 ° to 28.83 °, and finally the head segment prepreg molding trace is obtained according to the selected end molding angle.
(2) Method for calculating forming track of barrel body end
Since the first and second derivatives (r++r', r++ ") of the barrel segment Gaussian curvature (K) and the shell radius r to the axial length z are both 0, the first derivative expression of the barrel segment trajectory shaping angle (α) to the axial length (z) is reduced to:
as shown in figure 3, R is min The initial forming angle is 20 ° and the blue and red areas are ranges of prepreg forming angles for given barrel dimensions and prepreg dimensions and performance, as can be obtained from the graph, the final forming angle is 0.497 ° to 42.48 °. And finally, obtaining the molding track of the prepreg of the body section according to the selected termination molding angle.
Performing deformation and integral treatment on the (7) to obtain a wrinkle-free forming track at an initial forming angle alpha on the barrel section 0 Changing to the axial length L required to terminate the forming angle alpha process
L＝|R min (sinα-sinα 0 )| (8)
The axial length of the forming track in three areas (I, II and III areas) of the barrel section can be designed and calculated according to the formula (8).
2. Main algorithm for calculating defect-free forming track of shell seal head
The design of the shell head section defect-free forming track is based on the analysis of the defect without folds, and the design of the defect without overlapping and gaps is carried out by combining the geometric parameters of the head curved surface and the prepreg. The specific design analysis is as follows:
firstly, equally dividing the axis of the seal head shown in fig. 4 into n-1 parts, taking a plane perpendicular to the axis through each equal division point, and defining the obtained plane as a cross section of the seal head structure; secondly, intersecting the cross section with the part shell to obtain intersecting lines of the outer surface of the end socket structure and the cross section, defining an array Z to represent the obtained intersecting lines, simultaneously measuring the length of each intersecting line, and marking the intersecting line with the minimum circumference as Z 1 . The molding process of the prepreg head section can be equivalent to contact fixation with n points of a curved surface, A1, A2 and A3 respectively represent three points of the prepreg passing through the curved surface of the head, and the molding angles of the prepreg passing through the three points are respectively alpha 1 、α 2 、α 3 。
As shown in fig. 5, when the prepreg with width W is molded at angle α, the width of the prepreg covered on the intersecting line is WL, and the number N of prepregs required to completely cover the circumference of the intersecting line at the molded angle α is calculated.
In the middle ofIs the intersecting line Z 1 Radius of the plane.
The number of the head section core mould complete envelope defect-free molding prepregs is obtained through calculation of (10), and the actual molding angle alpha is obtained because N is obtained by upward rounding c The calculation determination needs to be further modified.
3. Shell laser in-situ forming track enveloping algorithm
When the geometric dimensions of the shell, the prepreg and the minimum laying radius of the prepreg are given, the end-value forming angle range of the head section and the barrel section forming angle range can be obtained, and after the parameters are determined, the track analysis of the shell prepared by uniformly distributing the prepreg on the surface of the core mould is needed.
In the actual in-situ forming process, the prepreg starts from the left end socket polar hole, reaches the right end socket polar hole, then returns, staggers one yarn width at the equator of the cylinder body after one complete cycle, and then realizes full distribution through a plurality of cycles, but not all angles can realize uniform distribution, the central corner is an angle formed by the track of the doffing point of the prepreg on the core mould around the axis, and the condition of uniform distribution can be met only when the central corner reaches a specific value.
In prepreg in-situ forming, when the pressing roller moves back and forth for one cycle, the central corner rotated by the main shaft is theta, and the central corner meeting the structural condition that the prepreg is uniformly fully distributed on the core mold can often correspond to the following relationship:
wherein: : θ 1 Is the central corner of the end socket;
θ 2 is the central corner of the barrel section;
delta theta is a central rotation angle change value;
t is the whole number of turns of the core mold;
k/m is the remainder of the core mold rotation, and the requirement is in an irreducible true fraction form; k is the interval between two adjacent shaping at the shell body and takes the width of the prepreg as a unit standard.
Wherein: d, diameter of the cylinder body; w is the width of the prepreg; alpha min Is the minimum forming angle of the barrel body; y is an integer which divides the circumference of the barrel body into equal parts by the width of the prepreg, namely the number of forming turns required by uniformly distributing the prepreg on the barrel body.
And then giving a central rotation angle change value delta theta, calculating the k value range, selecting the k value range, and finally preparing an actual central rotation angle theta finally selected by the shell structure s . The analytical flow is shown in FIG. 6:
4. (1) laser in-situ forming of shell body trace enveloping algorithm without fold defect
According to the shell size parameters shown in fig. 7, shell wrinkle-free defect forming track simulation is carried out, and the front and rear seal heads are different in height, so that an unequal-pole hole shell is formed. The width of the prepreg is 6.35, the minimum fold-free forming radius of the plane is 300, the initial forming angles of the left hole and the right hole are respectively set to be 30 degrees and 60 degrees, the left end head angle range of the left end head and the right end head end forming angle is calculated to be [9.21 degrees, 18.01 degrees ] [20.60 degrees, 29.92 degrees ] ], the right end head angle range is calculated to be [16.39 degrees, 26.96 degrees ] [30.18 degrees, 41.68 degrees ] ], the left end head angle end forming angle is set to be 10 degrees, the right end head angle end forming angle is set to be 30 degrees, the constant forming angle selection range of the barrel section is calculated to be [0.27 degrees, 42.03 degrees ], and the constant forming angle of the barrel section is set to be 20 degrees.
Fig. 9 shows the prepreg forming effect of the shell with different forming turns, and it can be seen that the prepregs of the barrel section are uniformly and regularly arranged on the surface of the core mold at certain intervals except for the serious overlapping of the prepregs near the seal head.
With the increase of the number of forming turns, the prepreg gradually fills the surface of the core mold, and when the number of complete cycles reaches 52, the prepreg is completely filled on the surface of the core mold, so that the correctness of the procedure is verified, and an unequal hole shell prepreg forming effect diagram is given.
(2) Shell laser in-situ forming seal head defect-free track enveloping algorithm
Also according to the shell size parameters shown in fig. 7, the defect-free track simulation of the shell head section is carried out, and other parameters are unchanged except that the minimum fold-free forming radius of the plane is adjusted to be 30.
Fig. 11 is a diagram of a shell head section and an initial molding angle screening calculation, and by means of program calculation, the maximum strain value (blue curve) of a molding track corresponding to a given initial angle of the head section can be obtained, and compared with the maximum strain value (red line segment) of the prepreg, the initial molding angle range which can be selected for defect-free molding of the prepreg at the head can be obtained.
In the figure, the selection ranges of the defect-free initial forming angles of the left end socket and the right end socket are respectively as follows:
the initial forming angles of the left end socket and the right end socket are set to be-60 degrees and 60 degrees, namely, -36.2075 degrees, -89.9 degrees, -36.2075 degrees, 89.9 degrees and, -51.6159 degrees, -89.9 degrees, -51.6159 degrees and-89.9 degrees.
As shown in figure 12, the shell seal head defect-free track forming effect shows that the prepregs are uniformly distributed in the seal head section and the barrel section, and the width of one prepreg is staggered between adjacent prepregs, so that no overlapping and gap defects are generated. With the increase of the number of forming turns, the prepreg is gradually distributed on the surface of the core mold, and when the number of complete cycles of the prepreg of the left and right sealing heads reaches 17 and 14 respectively, the prepreg is completely distributed on the surface of the core mold, so that the correctness of the procedure is verified. Wherein L represents the length of the right end seal head track envelope shell, and can be designed according to actual requirements.
The above embodiments are not intended to limit the scope of the present invention, so: all equivalent changes in structure, shape and principle of the invention should be covered in the scope of protection of the invention.
Claims (2)
1. A design method for an automatic laying track of a composite material shell structure is characterized by comprising the following steps of: the method comprises the following steps:
step 1, performing a prepreg plane laying performance test, and determining a minimum radius Rmin of a prepreg plane laid without folds;
step 2, calculating curved surface parameters of the shell structure, and obtaining curved surface parameters, geodesic curvature (Kg) and Gaussian curvature (K) required by a laying track design method;
step 3, carrying out the calculation of a laying track without folds and gaps on the surface of the shell structure;
and 4, carrying out shell structure envelope analysis based on the fold-free and gap-free defect laying track on the shell surface and the parameter information of the curved surface of the revolving body, and uniformly distributing the prepreg on the surface of the shell structure.
2. A design method for an automatic laying track of a composite material shell structure is characterized by comprising the following steps of: in step 2, the shell structure is an unequal hole shell structure, the forming track without the fold defect is divided into a seal head area and a barrel area, and the barrel area is divided into three areas.
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