易碎复合材料的设计、制备工艺与性能试验研究
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摘要
近年来,在快速发展的兵器工业产品结构中,出现了一类特殊的复合材料,它一方面必需具备足够的强度和刚度以承受工作载荷,另一方面还必需能够在一定的触发条件下易于碎裂以实现某种功能。本文把具有此类工作机制的复合材料统称为“易碎复合材料”。像导弹发射筒盖等很多易碎复合材料结构传统上常常采用导爆索爆炸切割的方法来实现其瞬间碎裂功能。这种方法在确保结构按时碎裂方面十分可靠,但存在一定的缺点:其一是装机后的爆炸控制元件和火工品由于长期存放可能会失效;其二是爆炸时产生的冲击波可能会伤害结构内的电子元件。由此,寻找和开发适当的非爆炸碎裂方法正在成为兵器工业中易碎复合材料的研究热点。
本文在查阅国内外相关文献的基础上,归纳出易碎复合材料的工作机制,设计出了若干种新型易碎复合材料及其结构,并对它们的材料和结构设计、制备工艺和相应的碎裂功能进行了较系统的研究。
本文对短切玻纤/191树脂复合材料进行了拉伸强度试验,通过试验结果修正了短纤维复合材料的强度计算公式;结合易碎复合材料结构的受力特点和工作机制,本文建立了短纤维增强易碎复合材料的强度理论,为短纤维增强易碎复合材料结构强度设计提供了理论基础,并建立了针对短切玻纤/191树脂复合材料的试验资料数据库。
作为一个应用实例,本文考察并借鉴鸡蛋可承受较大的均布压力的生物力学性能,根据所建立的短纤维增强易碎复合材料强度理论,从仿生学角度出发,设计并制备了一种短纤维增强191树脂易碎复合材料导流罩结构。通过对该结构试样的抗压性能和冲击性能模拟试验,证明所设计的仿生易碎复合材料导流罩能满足易碎复合材料工作机制的要求。
本文受凤仙花种子苞荚弹射传播机理的启发,设计并制备了仿生易碎复合材料迫击炮弹壳,然后对其进行了性能模拟试验。抗压和冲击模拟试验结果表明,所设计的仿生易碎复合材料迫击炮弹壳可以在空中运行时抵抗所受到的空气阻力以保护壳体内的生化物质,而在冲击力的作用下,会有规律的断裂并弹开,有效的释放出生化活性物质。有限元数值仿真结果与试验结果基本吻合。
本文利用单向连续纤维层板具有纵向抗拉强度高而横向易于被撕裂的特点,在制备好的单向层板上垂直于纤维方向预制了刻槽,然后将单向层板正交复合而制备成正交各向异性易碎复合材料层合板。文中对这种层合板作了承压试验与冲击试验,试验结果表明,所设计并制备的正交各向异性易碎复合材料层合板试样可承受一定的均布载荷,而在反向受到冲击力时,试样迅速沿着预制刻槽开裂,满足设计要求。
本文借用Y.Estrin和A.V.Dyskin提出的拓扑互锁材料设计新概念,并参照中国古代智力玩具“鲁班锁”的思维,提出一种拓扑互锁易碎复合材料新型结构。作为应用实例,文中设计并制备了深海导弹潜射系统隔水罩的模型试件,并对试件进行了性能模拟试验。试验结果表明,所设计的新型拓扑互锁易碎复合材料隔水罩可以承受给定的均匀水压,满足其工作要求;当在反向受到一定的冲击力时,结构可完成触发碎裂的工作机制。
本文从断裂力学理论出发,通过材料配方的设计使短纤维增强树脂复合材料沿厚度方向的断裂韧性值K_(IC)呈梯度变化,根据所推导出的材料配方制备出了K_(IC)梯度易碎复合材料板。采用落重冲击试验方法模拟K_(IC)梯度复合材料板受到撞击触发条件而破坏的情形,观察了破坏后的试样裂纹扩展情况,分析了试样的断口形貌和破坏模式。试验结果表明,所设计的K_(IC)梯度易碎复合材料板受到冲击等触发条件而破坏后,产生的裂纹在低K_(IC)层面内快速扩展;而沿着厚度方向,随着纤维含量的增大,K_(IC)值逐渐增大,纤维对裂纹起到有效地阻滞作用,使裂纹扩展缓慢,直至终止。
本文的研究工作在以下几方面取得了新的进展:
1.汇总了兵器工业及某些民用工业在近年发展和推出的一类材料结构的共同工作机制,首次提出“易碎复合材料”的概念。
2.首次建立了短纤维易碎复合材料的强度理论,为其材料和结构设计提供了理论基础。
3.首次从仿生学角度出发,根据种子苞荚弹射传播机理,设计并制备了连续纤维预应力弹射易碎复合材料迫击炮弹壳结构。
4.首次根据拓扑互锁原理,提出并设计了一种新型易碎复合材料结构,丰富了易碎复合材料结构的非爆炸触发碎裂结构形式。
5.首次利用材料配方设计并制备了一种可以控制裂纹扩展规律的短纤维增强树脂K_(IC)梯度复合材料。
In the structure of weapon industrial products fast developed recently, appeared a special kind of composites which have to have not only sufficient strength and stiffness to bear its working load but also ability to disintegrate in some specific triggering conditions. With this character of working mechanism this kind of composites are called "fragile composites" in this paper. For many fragile composite structures, such as the cover of missile launch canister etc., the function of disintegrating was implemented by explosive cut of blasting fuse. This method is reliable to ensure the structure disintegrating on time but there exist some drawbacks for it. The first one is that the electron component and initiating explosive device would be disabled after long-term deposition, and the second is that the blow wave of the explosive would hurt the electronic instrument inside the missile head. Therefore, to sought and develop new non-explosive fragmentation method is now becoming the focus of study on the fragile composites in weapon industry.
According to the related literatures home and abroad, the working mechanism of fragile composites was proposed and some new fragile composites and structures were designed in this paper. Meanwhile, the design of material and its structure, and its preparation technology and fragmentation character were systematically studied.
In this paper, the formula for calculating the strength of the short fiber reinforced composites was modified according to the tensile testing results of short glass fiber /191 resin composites. The failure criteria for short fiber fragile composites was established which provided a theoretical basis for the design of short fiber fragile composites. And also the testing database for short glass fiber /191 resin composites was established.
The biomechanical property of eggs which can bear large uniform pressure was studied, and based on the failure criteria of short fiber fragile composites a short fiber/191 resin composite dome was designed as an application example. The results of the compressive test and the impact test showed that the fragile composite dome meets the requirements of its working mechanism.
In this paper, a prestressed continuous fiber reinforced ejection fragile composite mortar case was designed based on the ejection propagation mechanism of the garden balsam seeds, and the mortar case model was prepared by filament winding process. The results of the compressive test and the impact test showed that the fragile composite mortar case can bear the air resistance to protect the biochemical substance in the shell and the mortar case will regularly fracture and release the biochemical substance under the impact. The numerical results agree well with the experimental results.
According to the characteristics of unidirectional composites which tensile strength along the fiber direction is much higher than that along the direction vertical to the fiber a groove was made perpendicular to fiber direction, and then the orthotropic fragile composite laminate was prepared by these unidirection plies with grooves. The results of the compressive test and the impact test showed that the orthotropic fragile composite laminate can bear given uniform pressure, and will rapidly fracture along the pre-cast groove under impact.
In this paper, based on a new concept of material design using regular assemblies of topologically interlocked elements proposed by Y. Estrin and A. V. Dyskin, and also based on the idea of "lu ban lock", a Chinese ancient educational toy, a new topologically interlocked fragile composite structure was proposed. As an application example, the model of water-resisting cover of deep sea missile launcher system was designed and its test specimen was prepared. The results of the simulation test showed that the topologically interlocked composite water-resisting cover can bear certain uniform water pressure, and will rapidly fracture under the reverse impact.
In the last part of this paper, starting from fracture mechanics theory, a K_(IC) gradient composite plate which actively control the crack growth was designed and prepared with different material prescriptions in different layers. The crack propagation and the fracture morphology were observed by scanning electron microscopy (SEM). Results showed that the crack propagated rapidly in the layers with lower value of K_(IC), howether, the crack propagated difficultlyalong with the thickness direction.
Summarily, some new development was made in this paper in the following aspects:
1. The concept of "fragile composites" was firstly put forward based on their common character of working mechanism.
2. The failure criteria of short fiber fragile composites was firstly established. The failure criteria provides a theoretical basis for the design of short fiber fragile composites.
3. Starting from Bionics, the prestressed continuous fiber ejection fragile composite mortar case was designed and prepared based on the ejection propagation mechanism of the garden balsam seeds, firstly.
4. A new topologically interlocked fragile composite structure was put forward and designed. This structure will enrich the non-explosive trigger fragmentation methods of the fragile composite structure.
5. A K_(IC) gradient composite plate which actively control the crackgrowth was designed and prepared with different material prescriptions in different layers, firstly.
本文在查阅国内外相关文献的基础上,归纳出易碎复合材料的工作机制,设计出了若干种新型易碎复合材料及其结构,并对它们的材料和结构设计、制备工艺和相应的碎裂功能进行了较系统的研究。
本文对短切玻纤/191树脂复合材料进行了拉伸强度试验,通过试验结果修正了短纤维复合材料的强度计算公式;结合易碎复合材料结构的受力特点和工作机制,本文建立了短纤维增强易碎复合材料的强度理论,为短纤维增强易碎复合材料结构强度设计提供了理论基础,并建立了针对短切玻纤/191树脂复合材料的试验资料数据库。
作为一个应用实例,本文考察并借鉴鸡蛋可承受较大的均布压力的生物力学性能,根据所建立的短纤维增强易碎复合材料强度理论,从仿生学角度出发,设计并制备了一种短纤维增强191树脂易碎复合材料导流罩结构。通过对该结构试样的抗压性能和冲击性能模拟试验,证明所设计的仿生易碎复合材料导流罩能满足易碎复合材料工作机制的要求。
本文受凤仙花种子苞荚弹射传播机理的启发,设计并制备了仿生易碎复合材料迫击炮弹壳,然后对其进行了性能模拟试验。抗压和冲击模拟试验结果表明,所设计的仿生易碎复合材料迫击炮弹壳可以在空中运行时抵抗所受到的空气阻力以保护壳体内的生化物质,而在冲击力的作用下,会有规律的断裂并弹开,有效的释放出生化活性物质。有限元数值仿真结果与试验结果基本吻合。
本文利用单向连续纤维层板具有纵向抗拉强度高而横向易于被撕裂的特点,在制备好的单向层板上垂直于纤维方向预制了刻槽,然后将单向层板正交复合而制备成正交各向异性易碎复合材料层合板。文中对这种层合板作了承压试验与冲击试验,试验结果表明,所设计并制备的正交各向异性易碎复合材料层合板试样可承受一定的均布载荷,而在反向受到冲击力时,试样迅速沿着预制刻槽开裂,满足设计要求。
本文借用Y.Estrin和A.V.Dyskin提出的拓扑互锁材料设计新概念,并参照中国古代智力玩具“鲁班锁”的思维,提出一种拓扑互锁易碎复合材料新型结构。作为应用实例,文中设计并制备了深海导弹潜射系统隔水罩的模型试件,并对试件进行了性能模拟试验。试验结果表明,所设计的新型拓扑互锁易碎复合材料隔水罩可以承受给定的均匀水压,满足其工作要求;当在反向受到一定的冲击力时,结构可完成触发碎裂的工作机制。
本文从断裂力学理论出发,通过材料配方的设计使短纤维增强树脂复合材料沿厚度方向的断裂韧性值K_(IC)呈梯度变化,根据所推导出的材料配方制备出了K_(IC)梯度易碎复合材料板。采用落重冲击试验方法模拟K_(IC)梯度复合材料板受到撞击触发条件而破坏的情形,观察了破坏后的试样裂纹扩展情况,分析了试样的断口形貌和破坏模式。试验结果表明,所设计的K_(IC)梯度易碎复合材料板受到冲击等触发条件而破坏后,产生的裂纹在低K_(IC)层面内快速扩展;而沿着厚度方向,随着纤维含量的增大,K_(IC)值逐渐增大,纤维对裂纹起到有效地阻滞作用,使裂纹扩展缓慢,直至终止。
本文的研究工作在以下几方面取得了新的进展:
1.汇总了兵器工业及某些民用工业在近年发展和推出的一类材料结构的共同工作机制,首次提出“易碎复合材料”的概念。
2.首次建立了短纤维易碎复合材料的强度理论,为其材料和结构设计提供了理论基础。
3.首次从仿生学角度出发,根据种子苞荚弹射传播机理,设计并制备了连续纤维预应力弹射易碎复合材料迫击炮弹壳结构。
4.首次根据拓扑互锁原理,提出并设计了一种新型易碎复合材料结构,丰富了易碎复合材料结构的非爆炸触发碎裂结构形式。
5.首次利用材料配方设计并制备了一种可以控制裂纹扩展规律的短纤维增强树脂K_(IC)梯度复合材料。
In the structure of weapon industrial products fast developed recently, appeared a special kind of composites which have to have not only sufficient strength and stiffness to bear its working load but also ability to disintegrate in some specific triggering conditions. With this character of working mechanism this kind of composites are called "fragile composites" in this paper. For many fragile composite structures, such as the cover of missile launch canister etc., the function of disintegrating was implemented by explosive cut of blasting fuse. This method is reliable to ensure the structure disintegrating on time but there exist some drawbacks for it. The first one is that the electron component and initiating explosive device would be disabled after long-term deposition, and the second is that the blow wave of the explosive would hurt the electronic instrument inside the missile head. Therefore, to sought and develop new non-explosive fragmentation method is now becoming the focus of study on the fragile composites in weapon industry.
According to the related literatures home and abroad, the working mechanism of fragile composites was proposed and some new fragile composites and structures were designed in this paper. Meanwhile, the design of material and its structure, and its preparation technology and fragmentation character were systematically studied.
In this paper, the formula for calculating the strength of the short fiber reinforced composites was modified according to the tensile testing results of short glass fiber /191 resin composites. The failure criteria for short fiber fragile composites was established which provided a theoretical basis for the design of short fiber fragile composites. And also the testing database for short glass fiber /191 resin composites was established.
The biomechanical property of eggs which can bear large uniform pressure was studied, and based on the failure criteria of short fiber fragile composites a short fiber/191 resin composite dome was designed as an application example. The results of the compressive test and the impact test showed that the fragile composite dome meets the requirements of its working mechanism.
In this paper, a prestressed continuous fiber reinforced ejection fragile composite mortar case was designed based on the ejection propagation mechanism of the garden balsam seeds, and the mortar case model was prepared by filament winding process. The results of the compressive test and the impact test showed that the fragile composite mortar case can bear the air resistance to protect the biochemical substance in the shell and the mortar case will regularly fracture and release the biochemical substance under the impact. The numerical results agree well with the experimental results.
According to the characteristics of unidirectional composites which tensile strength along the fiber direction is much higher than that along the direction vertical to the fiber a groove was made perpendicular to fiber direction, and then the orthotropic fragile composite laminate was prepared by these unidirection plies with grooves. The results of the compressive test and the impact test showed that the orthotropic fragile composite laminate can bear given uniform pressure, and will rapidly fracture along the pre-cast groove under impact.
In this paper, based on a new concept of material design using regular assemblies of topologically interlocked elements proposed by Y. Estrin and A. V. Dyskin, and also based on the idea of "lu ban lock", a Chinese ancient educational toy, a new topologically interlocked fragile composite structure was proposed. As an application example, the model of water-resisting cover of deep sea missile launcher system was designed and its test specimen was prepared. The results of the simulation test showed that the topologically interlocked composite water-resisting cover can bear certain uniform water pressure, and will rapidly fracture under the reverse impact.
In the last part of this paper, starting from fracture mechanics theory, a K_(IC) gradient composite plate which actively control the crack growth was designed and prepared with different material prescriptions in different layers. The crack propagation and the fracture morphology were observed by scanning electron microscopy (SEM). Results showed that the crack propagated rapidly in the layers with lower value of K_(IC), howether, the crack propagated difficultlyalong with the thickness direction.
Summarily, some new development was made in this paper in the following aspects:
1. The concept of "fragile composites" was firstly put forward based on their common character of working mechanism.
2. The failure criteria of short fiber fragile composites was firstly established. The failure criteria provides a theoretical basis for the design of short fiber fragile composites.
3. Starting from Bionics, the prestressed continuous fiber ejection fragile composite mortar case was designed and prepared based on the ejection propagation mechanism of the garden balsam seeds, firstly.
4. A new topologically interlocked fragile composite structure was put forward and designed. This structure will enrich the non-explosive trigger fragmentation methods of the fragile composite structure.
5. A K_(IC) gradient composite plate which actively control the crackgrowth was designed and prepared with different material prescriptions in different layers, firstly.
引文
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