大张力缠绕碳纤维复合材料高速飞轮转子研究
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摘要
碳纤维复合材料由于其较高的比强度、比刚度以及不产生高频涡流损耗等特点,日益广泛地被用来制造高速飞轮转子护套。另外,大张力缠绕相比压装等工艺更适用于施加碳纤维复合材料层与金属轮毂间的过盈配合。研究了大张力缠绕复合材料飞轮转子护套的设计与成型工艺,建立了复合材料护套的三维有限元模型,采用温差法模拟纤维缠绕张力,采用单元生死法模拟逐层缠绕及固化过程。在30000 RPM的转速及不同工作温度下,分析了缠绕张力及轮毂和转轴间过盈量对转子各材料界面处压应力的影响规律。此外,采用大张力缠绕工艺制备了高速飞轮转子碳纤维护套样件,测试了样件护套对金属轮毂的径向压应力以及轮毂径向应变。结果表明,基于仿真模型的计算值与样件测试值吻合良好,获得了飞轮转子的最佳几何外形和制备工艺参数,使转子的最大工作外缘线速度达697 m/s,最大储能密度为44.5 Wh/kg。研究成果对复合材料高速飞轮转子护套的设计与制造具有重要的意义。
The carbon fiber composite has been widely applied to manufacture high speed flywheel rotor sheath for its high specific strength,specific stiffness,and absence of high frequency eddy current power loss. Moreover,compared with the press-fitted process,the large tension winding process is more suitable for applying the interference fit between the carbon fiber composite sheath and the metal hub. In this paper,the design and forming process of the large tension winding composite sheath of the flywheel rotor was discussed. A three-dimensional finite element model of composite flywheel rotor has been built. The filament winding tension was applied by using temperature difference method. And the winding and curing processes were simulated by the element deletion method. The influence of the winding tension and the interference between the hub and the shaft on the compressive stress at the interface of the rotor was analyzed at the speed of 30000 RPM and the different operating temperature. In addition,the specimens of composite sheath of high speed flywheel rotor were prepared by the large tension winding technology.The radial compressive stress of the sheath on hub and the radial strain of the hub were tested. The results show that the calculated values were in agreement with the measured values of specimens. The optimum geometry and technological parameters of the composite flywheel rotor were obtained. The maximum energy storage density was 44. 5 Wh/kg,while the peripheral speed was 697 m/s. The results of this paper are of important significance to the design and manufacture of composite high speed flywheel rotor sheath.
The carbon fiber composite has been widely applied to manufacture high speed flywheel rotor sheath for its high specific strength,specific stiffness,and absence of high frequency eddy current power loss. Moreover,compared with the press-fitted process,the large tension winding process is more suitable for applying the interference fit between the carbon fiber composite sheath and the metal hub. In this paper,the design and forming process of the large tension winding composite sheath of the flywheel rotor was discussed. A three-dimensional finite element model of composite flywheel rotor has been built. The filament winding tension was applied by using temperature difference method. And the winding and curing processes were simulated by the element deletion method. The influence of the winding tension and the interference between the hub and the shaft on the compressive stress at the interface of the rotor was analyzed at the speed of 30000 RPM and the different operating temperature. In addition,the specimens of composite sheath of high speed flywheel rotor were prepared by the large tension winding technology.The radial compressive stress of the sheath on hub and the radial strain of the hub were tested. The results show that the calculated values were in agreement with the measured values of specimens. The optimum geometry and technological parameters of the composite flywheel rotor were obtained. The maximum energy storage density was 44. 5 Wh/kg,while the peripheral speed was 697 m/s. The results of this paper are of important significance to the design and manufacture of composite high speed flywheel rotor sheath.
引文
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[4]汪勇,戴兴建,孙清德.基于有限元的金属飞轮结构设计优化[J].储能科学与技术,2015(3):267-272.
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[6]白越,黎海文,吴一辉,等.复合材料飞轮转子设计[J].光学精密工程,2007,15(6):852-857.
[7]宋以国,李翀,李文逸.复合材料飞轮转子成型工艺的有限元模拟[J].机械科学与技术,2013,32(10):1456-1460.
[8]丁世海,李奕良,戴兴建.复合材料飞轮结构有限元分析与旋转强度试验[J].机械科学与技术,2008,27(3):301-304.
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[10]Arvin A C,Bakis C E.Optimal design of press-fitted filament wound composite flywheel rotors[J].Composite Structures,2006,72(1):47-57.
[11]Hiroshima N,Hatta H,Koyama M,et al.Optimization of flywheel rotor made of three-dimensional composites[J].Composite Structures,2015,131:304-311.
[12]Ha S K,Yoon Y B,Han S C.Effects of material properties on the total stored energy of a hybrid flywheel rotor[J].Archive of Applied Mechanics,2000,70(8-9):571-584.
[13]胡小飞,刘刚,孙津济,等.Homopolar型径向磁轴承转子涡流损耗的分析与优化[J].系统仿真学报,2013,25(12).
[14]胡宝刚,赵建设.碳纤维复合材料的后加工工艺[J].宇航材料工艺,1995(1):31-34.
[15]鲍永杰,高航.碳纤维复合材料构件加工缺陷与高效加工对策[C]//SAMPE CHINA 2009暨中国国际先进材料与工艺技术学术研讨会.2009.
[16]Barbero E J.Finite element analysis of composite materials using ANSYS,second edition[M].CRC Press,2013.
[17]许家忠.纤维缠绕复合材料成型原理及工艺[M].北京:科学出版社,2013.
[2]孔德群,裴艳敏,邢立业,等.储能飞轮转子用金属材料的研究现状[J].储能科学与技术,2014,3(1):30-35.
[3]戴兴建,孟亚锋.复合材料储能飞轮结构强度技术研究进展[J].机械工程师,2005(4):7-9.
[4]汪勇,戴兴建,孙清德.基于有限元的金属飞轮结构设计优化[J].储能科学与技术,2015(3):267-272.
[5]张建成.用于配电网的飞轮储能系统设计[J].华北电力大学学报(自然科学版),2005,32(s1):38-40.
[6]白越,黎海文,吴一辉,等.复合材料飞轮转子设计[J].光学精密工程,2007,15(6):852-857.
[7]宋以国,李翀,李文逸.复合材料飞轮转子成型工艺的有限元模拟[J].机械科学与技术,2013,32(10):1456-1460.
[8]丁世海,李奕良,戴兴建.复合材料飞轮结构有限元分析与旋转强度试验[J].机械科学与技术,2008,27(3):301-304.
[9]Ha S K,Kim M H,Han S C,et al.Design and spin test of a hybrid composite flywheel rotor with a split type hub[J].Journal of Composite Materials,2006,40(23):2113-2130.
[10]Arvin A C,Bakis C E.Optimal design of press-fitted filament wound composite flywheel rotors[J].Composite Structures,2006,72(1):47-57.
[11]Hiroshima N,Hatta H,Koyama M,et al.Optimization of flywheel rotor made of three-dimensional composites[J].Composite Structures,2015,131:304-311.
[12]Ha S K,Yoon Y B,Han S C.Effects of material properties on the total stored energy of a hybrid flywheel rotor[J].Archive of Applied Mechanics,2000,70(8-9):571-584.
[13]胡小飞,刘刚,孙津济,等.Homopolar型径向磁轴承转子涡流损耗的分析与优化[J].系统仿真学报,2013,25(12).
[14]胡宝刚,赵建设.碳纤维复合材料的后加工工艺[J].宇航材料工艺,1995(1):31-34.
[15]鲍永杰,高航.碳纤维复合材料构件加工缺陷与高效加工对策[C]//SAMPE CHINA 2009暨中国国际先进材料与工艺技术学术研讨会.2009.
[16]Barbero E J.Finite element analysis of composite materials using ANSYS,second edition[M].CRC Press,2013.
[17]许家忠.纤维缠绕复合材料成型原理及工艺[M].北京:科学出版社,2013.