先进复合材料格栅结构软模辅助共固化工艺研究
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摘要
先进复合材料格栅结构(AGS)是一种综合了材料技术与结构设计优点的新型空间点阵结构,具有轻质高强、耐腐蚀、可设计、高损伤容限与环境鲁棒性等优点,已被广泛应用于航空、航天、轮船等运载器中,成为具有发展前景的新型承力结构构型之一。但由于其在制备过程中出现极其复杂的多物理场耦合行为,导致其制备工艺设计复杂、产品良品率低等问题,限制了其应用范围的扩大。本论文首先对AGS的制备工艺开展了相应的研究,在此基础上,提出了一种以硅橡胶为整体芯模的软模辅助共固化工艺改进方案；然后,分别采用实验和数值仿真的方法对其在制备过程中出现的多物理场耦合行为进行了研究,以验证该工艺方案的可行性,并提出了改进制备工艺的措施；最后,开发了相应的集成分析软件包AGSCURE,此软件包将为AGS的制备工艺参数设计提供一个有效的分析工具。本论文工作是国家自然科学基金重点项目“面向近空间飞行器的多功能超轻质结构设计优化理论”(90816025)和国家自然科学基金面上项目“先进复合材料网格结构共固化工艺与软模成型参数优化分析”(10702012)课题中的重要研究内容之一
论文的主要研究内容和成果如下：
1.硅橡胶为整体芯模的软模辅助共固化工艺的实验研究和光纤布拉格光栅为传感器的在线监测方案探讨
(1)通过对典型AGS的软模辅助共固化工艺制备实验说明,硅橡胶整体芯模降低了芯模的制备、装配和定位要求,开槽底部连续硅橡胶产生的膨胀压力促进了肋骨预浸料中纤维床的压实,提高了网格肋骨与蒙皮间的连接质量,并简化了脱模操作。
(2)由布置于试件内自封装增敏型光纤布拉格光栅温度传感器和应变传感器监测结果证明,软模辅助共固化工艺在AGS制备中具有可行性与有效性。
2.先进复合材料格栅结构软模辅助共固化工艺的数值仿真研究
(1)由于目前先进复合材料的工艺力学研究,大部分分析模型仅考虑了先进复合材料结构,忽略了模具、辅助材料对其固化行为的影响,在某些情况下,这种简化模型将对软模辅助共固化工艺中AGS的温度传导问题产生较大误差。为此,作者提出了一种采用接触约束描述模具与辅助材料对AGS固化行为影响的方法,并以典型AGS的软模辅助共固化工艺为例,提出了实现在数值仿真中分析精度与计算效率间平衡的措施。
(2)由于在制备过程中树脂基体热力学性能变化、增强纤维与树脂基体间热力学性能不匹配和组成结构的各构件刚度差异等因素的影响,导致了先进复合材料结构成型后其残余应力分布的复杂性,为此,本文采用考虑松弛效应的等效弹性方法和复合材料细观力学理论实现了各向异性先进复合材料黏弹性行为的模拟,提高了现有先进复合材料残余应力发展分析模型的效率与精度,并以该模型研究了软模辅助共固化工艺中AGS残余应力的发展规律。
(3)在软模辅助共固化工艺中,准确确定工艺间隙是先进复合材料结构受到均匀、同步固化压力的保障,为此,本文采用弹性接触理论的有限元方法来设计硅橡胶芯模尺寸,并以典型算例研究了工艺间隙对AGS所受膨胀压力分布规律的影响。通过对比已有的热弹性方法设计结果,说明了该方法的优越性。
3.先进复合材料格栅结构软模辅助共固化工艺的集成分析程序包AGSCURE的开发和制备工艺参数研究
(1)基于上述实验和数值仿真研究的成果,开发了模拟AGS软模辅助共固化工艺过程的集成分析程序包AGSCURE,该软件包可用于AGS的工艺参数设计。
(2)基于AGSCURE软件包通过对典型AGS制备工艺过程的仿真和工艺参数研究,发现了AGS的几何因素对其固化行为和树脂流动行为影响的规律,如肋骨宽度对温度场分布的影响比肋骨高度明显,而树脂粘度变化对肋骨高度更敏感；热压釜提供的固化压力无法驱使尺寸较大AGS预浸料内发生有效的树脂流动与纤维床压实行为。
本论文所提出的软模辅助共固化工艺方案、分析模型、理论和所得到的结论将对AGS低成本、整体化制备工艺的设计和研究具有一定的工程和科学价值。
Advanced composite grid-stiffened structure (AGS) is a new type of lattice structures which combines the characteristics of material technique and structure design. Due to the advantages such as light weight, high strength, corrosion resistance, high damage tolerance and environmental robust, the structure has been widely used in aviation, aerospace, shipping etc. and became a kind of competing engineering structure, However, its application would be discouraged because of the extremely complicated coupling behavior between curing, temperature and pressure field etc. during the manufacturing process, and due to the complex fabrication process, low quality product, difficult process design and etc. factors. Therefore, the research of technical mechanics during the manufacturing process for AGS has been carried out in the thesis. Firstly, based on the review of existing manufacturing process, an improved technical scheme called soft-mold assisted co-curing process was proposed, which employs an integrated silicon mold as the mandrel. Then, the multi-fields coupling behavior was studied by experiments and numerical simulations, respectively to examine the feasibility of the provided scheme. Lastly, by the integrated software package AGSCURE developed by author, a numerical simulation of a typical AGS component in the scheme was worked out, and some suggestions for the co-curing process execution were proposed. The research contents in the thesis are a part of the project of National Key Science Foundation in China "The research of multifunction super lightweight structural design theory and optimization for the near space aerocraft"(90816025) and the National Natural Science Foundation in China "The study of soft-mold aided co-curing process and parameters optimization for the advanced composite grid-stiffened structures"(10702012).
The main research contents and achievements can be summarized as follows:
1. Experimental study on soft-mold aided co-curing process and establish the on-line monitoring scheme with embedded fiber Brag grating sensors.
(1) The experimental study of AGS specimens manufactured by the soft-mold aided co-curing process indicates that (a) reducing the requirements of molds assembly and position by employing a silicon rubber mandrel,(b) simplified the de-molding operation,(c) enhancing the compaction of fibers bed and quality of the interface between skin and grids. Hence, it demonstrates the feasibility of the provided scheme.
(2) An on-line monitoring scheme employing embedded improved fiber Brag grating sensors was proposed for acquiring the variations of temperature and strain in AGS during the manufacturing process, and the acquired data shows the feasibility and effectiveness of the soft-mold aided co-curing process.
2. Numerical simulate the multi-fields coupling behavior of soft-mold aided co-curing process of AGS.
(1) In the study of advanced composite manufacturing process, most of the analysis models just focus on advanced composite structure parts and ignore the effect of molds and aided materials on the curing behavior of advanced composite. However, the simplified model is inappropriate for the thermal conduction research of soft-mold aided co-curing process for AGS. Therefore, the author suggested that the issue would be solved by defining a contact constraint between the molds and AGS. It was proved that the model would counterpoise the requirements between analysis precision and simulation efficiency by the simulation of the soft-mold aided co-curing process for an AGS component.
(2) The variation of resin thermo-mechanical properties, mismatch of thermo-mechanical properties between reinforced fiber and resin matrix and different of stiffness between sub-structures etc. are the sources of residual stresses in an advanced composite structure. In this thesis, an equivalent elastic method combining the laxation effect of resin and mesomechanics model of composite for depicting the anisotropic viscoelastic properties of advanced composite materials was proposed and applied in the analysis for improving the accuracy and effectiveness of the residual stresses prediction. Employing the model, the feature of residual stresses development in AGS during the soft-mold aided co-curing process was investigated by a series of numerical simulations.
(3) A precise technologic gap is the guarantee for applying a uniform and synchronous pressure on AGS during the soft-mold aided co-curing process. Therefore, an improved means for design the silicon rubber mandrel was proposed which combines the elastic contact theory and finite element method, the effect of technologic gap on the distribution of contact pressure provided by the swelling soft-mold was investigated by a series of numerical simulations, and the advantages of it was shown by contrasting to the traditional thermal elastic means.
3. Develop an integrated software package AGSCURE for simulating the scheme of soft-mold aided co-curing process, and discuss the effect of technical parameters on the product quality of AGS.
(1) Based on the results of experiments and numerical simulations, an integrated software package AGSCURE for simulating the soft-mold aided co-curing process was developed. The software package would be useful for the process design for AGS.
(2) Based on a parametric study employing the AGSCURE, the discipline of geometric size of AGS on the curing and resin flow behavior was investigated. For example, the distribution of temperature is mainly effected by the width of ribs while the variation of resin viscosity is mainly effected by the height of ribs, and the autoclave pressure can't drive the resin flow and fiber bed compaction in an AGS effectively.
The scheme, analysis models, method and conclusions of soft-mold aided co-curing process proposed in the thesis would be benefit for engineers in design a low-cost and integral manufacturing process of AGS.
论文的主要研究内容和成果如下：
1.硅橡胶为整体芯模的软模辅助共固化工艺的实验研究和光纤布拉格光栅为传感器的在线监测方案探讨
(1)通过对典型AGS的软模辅助共固化工艺制备实验说明,硅橡胶整体芯模降低了芯模的制备、装配和定位要求,开槽底部连续硅橡胶产生的膨胀压力促进了肋骨预浸料中纤维床的压实,提高了网格肋骨与蒙皮间的连接质量,并简化了脱模操作。
(2)由布置于试件内自封装增敏型光纤布拉格光栅温度传感器和应变传感器监测结果证明,软模辅助共固化工艺在AGS制备中具有可行性与有效性。
2.先进复合材料格栅结构软模辅助共固化工艺的数值仿真研究
(1)由于目前先进复合材料的工艺力学研究,大部分分析模型仅考虑了先进复合材料结构,忽略了模具、辅助材料对其固化行为的影响,在某些情况下,这种简化模型将对软模辅助共固化工艺中AGS的温度传导问题产生较大误差。为此,作者提出了一种采用接触约束描述模具与辅助材料对AGS固化行为影响的方法,并以典型AGS的软模辅助共固化工艺为例,提出了实现在数值仿真中分析精度与计算效率间平衡的措施。
(2)由于在制备过程中树脂基体热力学性能变化、增强纤维与树脂基体间热力学性能不匹配和组成结构的各构件刚度差异等因素的影响,导致了先进复合材料结构成型后其残余应力分布的复杂性,为此,本文采用考虑松弛效应的等效弹性方法和复合材料细观力学理论实现了各向异性先进复合材料黏弹性行为的模拟,提高了现有先进复合材料残余应力发展分析模型的效率与精度,并以该模型研究了软模辅助共固化工艺中AGS残余应力的发展规律。
(3)在软模辅助共固化工艺中,准确确定工艺间隙是先进复合材料结构受到均匀、同步固化压力的保障,为此,本文采用弹性接触理论的有限元方法来设计硅橡胶芯模尺寸,并以典型算例研究了工艺间隙对AGS所受膨胀压力分布规律的影响。通过对比已有的热弹性方法设计结果,说明了该方法的优越性。
3.先进复合材料格栅结构软模辅助共固化工艺的集成分析程序包AGSCURE的开发和制备工艺参数研究
(1)基于上述实验和数值仿真研究的成果,开发了模拟AGS软模辅助共固化工艺过程的集成分析程序包AGSCURE,该软件包可用于AGS的工艺参数设计。
(2)基于AGSCURE软件包通过对典型AGS制备工艺过程的仿真和工艺参数研究,发现了AGS的几何因素对其固化行为和树脂流动行为影响的规律,如肋骨宽度对温度场分布的影响比肋骨高度明显,而树脂粘度变化对肋骨高度更敏感；热压釜提供的固化压力无法驱使尺寸较大AGS预浸料内发生有效的树脂流动与纤维床压实行为。
本论文所提出的软模辅助共固化工艺方案、分析模型、理论和所得到的结论将对AGS低成本、整体化制备工艺的设计和研究具有一定的工程和科学价值。
Advanced composite grid-stiffened structure (AGS) is a new type of lattice structures which combines the characteristics of material technique and structure design. Due to the advantages such as light weight, high strength, corrosion resistance, high damage tolerance and environmental robust, the structure has been widely used in aviation, aerospace, shipping etc. and became a kind of competing engineering structure, However, its application would be discouraged because of the extremely complicated coupling behavior between curing, temperature and pressure field etc. during the manufacturing process, and due to the complex fabrication process, low quality product, difficult process design and etc. factors. Therefore, the research of technical mechanics during the manufacturing process for AGS has been carried out in the thesis. Firstly, based on the review of existing manufacturing process, an improved technical scheme called soft-mold assisted co-curing process was proposed, which employs an integrated silicon mold as the mandrel. Then, the multi-fields coupling behavior was studied by experiments and numerical simulations, respectively to examine the feasibility of the provided scheme. Lastly, by the integrated software package AGSCURE developed by author, a numerical simulation of a typical AGS component in the scheme was worked out, and some suggestions for the co-curing process execution were proposed. The research contents in the thesis are a part of the project of National Key Science Foundation in China "The research of multifunction super lightweight structural design theory and optimization for the near space aerocraft"(90816025) and the National Natural Science Foundation in China "The study of soft-mold aided co-curing process and parameters optimization for the advanced composite grid-stiffened structures"(10702012).
The main research contents and achievements can be summarized as follows:
1. Experimental study on soft-mold aided co-curing process and establish the on-line monitoring scheme with embedded fiber Brag grating sensors.
(1) The experimental study of AGS specimens manufactured by the soft-mold aided co-curing process indicates that (a) reducing the requirements of molds assembly and position by employing a silicon rubber mandrel,(b) simplified the de-molding operation,(c) enhancing the compaction of fibers bed and quality of the interface between skin and grids. Hence, it demonstrates the feasibility of the provided scheme.
(2) An on-line monitoring scheme employing embedded improved fiber Brag grating sensors was proposed for acquiring the variations of temperature and strain in AGS during the manufacturing process, and the acquired data shows the feasibility and effectiveness of the soft-mold aided co-curing process.
2. Numerical simulate the multi-fields coupling behavior of soft-mold aided co-curing process of AGS.
(1) In the study of advanced composite manufacturing process, most of the analysis models just focus on advanced composite structure parts and ignore the effect of molds and aided materials on the curing behavior of advanced composite. However, the simplified model is inappropriate for the thermal conduction research of soft-mold aided co-curing process for AGS. Therefore, the author suggested that the issue would be solved by defining a contact constraint between the molds and AGS. It was proved that the model would counterpoise the requirements between analysis precision and simulation efficiency by the simulation of the soft-mold aided co-curing process for an AGS component.
(2) The variation of resin thermo-mechanical properties, mismatch of thermo-mechanical properties between reinforced fiber and resin matrix and different of stiffness between sub-structures etc. are the sources of residual stresses in an advanced composite structure. In this thesis, an equivalent elastic method combining the laxation effect of resin and mesomechanics model of composite for depicting the anisotropic viscoelastic properties of advanced composite materials was proposed and applied in the analysis for improving the accuracy and effectiveness of the residual stresses prediction. Employing the model, the feature of residual stresses development in AGS during the soft-mold aided co-curing process was investigated by a series of numerical simulations.
(3) A precise technologic gap is the guarantee for applying a uniform and synchronous pressure on AGS during the soft-mold aided co-curing process. Therefore, an improved means for design the silicon rubber mandrel was proposed which combines the elastic contact theory and finite element method, the effect of technologic gap on the distribution of contact pressure provided by the swelling soft-mold was investigated by a series of numerical simulations, and the advantages of it was shown by contrasting to the traditional thermal elastic means.
3. Develop an integrated software package AGSCURE for simulating the scheme of soft-mold aided co-curing process, and discuss the effect of technical parameters on the product quality of AGS.
(1) Based on the results of experiments and numerical simulations, an integrated software package AGSCURE for simulating the soft-mold aided co-curing process was developed. The software package would be useful for the process design for AGS.
(2) Based on a parametric study employing the AGSCURE, the discipline of geometric size of AGS on the curing and resin flow behavior was investigated. For example, the distribution of temperature is mainly effected by the width of ribs while the variation of resin viscosity is mainly effected by the height of ribs, and the autoclave pressure can't drive the resin flow and fiber bed compaction in an AGS effectively.
The scheme, analysis models, method and conclusions of soft-mold aided co-curing process proposed in the thesis would be benefit for engineers in design a low-cost and integral manufacturing process of AGS.
引文
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