工型加筋结构模具方案对共固化过程树脂压力及成型质量的影响
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摘要
以碳纤维/双马树脂复合材料工型加筋结构为研究对象,研究了模具方案对热压罐共固化过程树脂压力及成型质量的影响。对筋条两侧的模具采用了三种方案,即铝模/铝模、橡胶软模/铝模、拐角区预浸料增强橡胶软模/铝模。采用自主建立的树脂压力在线监测系统对三种模具方案下工型加筋结构内部树脂压力分布进行研究,进而结合制件尺寸及内部缺陷情况,分析模具方案对树脂流动、模具与预浸料铺层贴合程度及密实过程的影响。结果表明:橡胶软模能显著提高模具与预浸料的贴合程度,从而提高压力传递效率和密实程度;软模拐角区刚度对制件成型质量影响显著,拐角区刚度过低则成型中模具发生较大形变,不利于另一侧铝模与预浸料贴合以及制件尺寸精度的保证;适当提高软模拐角区刚度可提高密实压力均匀性和制件成型质量;适当刚度的橡胶软模和金属刚模配合方案对于加筋壁板结构的共固化工艺较为适用。
In this paper,the influences of mold scheme on resin pressure distribution and processing quality of carbon fiber/bismaleimide resin I-stiffened skin fabricated by autoclave co-cured process were studied. Three kinds of mold schemes for two sides of stiffener were designed,including aluminum mold/aluminum mold,rubber mold/aluminum mold and rubber mold with corner reinforced by prepreg/aluminum mold. And resin pressure distribution inside I-stiffened skin processed with these three mold schemes was investigated by means of self-developed resin pressure online monitoring system. Furthermore,considering dimension and inner defects of I-stiffened skin,the influences of mold scheme on resin flow,fitting state between mold and prepreg stack and compaction process of prepreg stack were studied. The results show that rubber mold significantly improves fitting degree between mold and prepreg stack,thus increasing pressure transferring efficiency of mold and compaction degree of composite. The stiffness of the corner in rubber mold has a significant impact on processing quality of I-stiffened skin. Too low corner stiffness results in larger deformation of mold during processing,which is detrimental to fitting degree between aluminum mold placed at the other side and prepreg stack. It also leads to decrease in dimensional accuracy of I-stiffened skin. Nevertheless,appropriately increasing the corner stiffness of rubber mold can improve uniformity of compaction pressure and processing quality. The mold scheme,which uses rubber mold with reasonable stiffness and metal mold,is suitable for fabricating stiffened skin structure using autoclave co-cured process.
In this paper,the influences of mold scheme on resin pressure distribution and processing quality of carbon fiber/bismaleimide resin I-stiffened skin fabricated by autoclave co-cured process were studied. Three kinds of mold schemes for two sides of stiffener were designed,including aluminum mold/aluminum mold,rubber mold/aluminum mold and rubber mold with corner reinforced by prepreg/aluminum mold. And resin pressure distribution inside I-stiffened skin processed with these three mold schemes was investigated by means of self-developed resin pressure online monitoring system. Furthermore,considering dimension and inner defects of I-stiffened skin,the influences of mold scheme on resin flow,fitting state between mold and prepreg stack and compaction process of prepreg stack were studied. The results show that rubber mold significantly improves fitting degree between mold and prepreg stack,thus increasing pressure transferring efficiency of mold and compaction degree of composite. The stiffness of the corner in rubber mold has a significant impact on processing quality of I-stiffened skin. Too low corner stiffness results in larger deformation of mold during processing,which is detrimental to fitting degree between aluminum mold placed at the other side and prepreg stack. It also leads to decrease in dimensional accuracy of I-stiffened skin. Nevertheless,appropriately increasing the corner stiffness of rubber mold can improve uniformity of compaction pressure and processing quality. The mold scheme,which uses rubber mold with reasonable stiffness and metal mold,is suitable for fabricating stiffened skin structure using autoclave co-cured process.
引文
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[21]卢鑫,孙志杰,李超,等.硅橡胶热膨胀工艺预浸料铺层内树脂压力变化规律[J].复合材料学报,2011(3):50-55.
[22]辛朝波,徐吉峰,顾轶卓,等.热压罐工艺树脂压力测试系统适用性实验研究[J].复合材料学报,2013(5):74-78.
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[27]Xin C,Gu Y,Li M,et al.Online monitoring and analysis of resin pressure inside composite laminate during zero-bleeding autoclave process[J].Polymer Composites,2011,32(2):314-323.
[28]Xin C,Li M,Gu Y,et al.Study on the resin flow and fiber compaction of tapered composite laminates during autoclave processing[J].Journal of Reinforced Plastics and Composites,2011,30(16):1399-1411.
[29]Gu Y,Xin C,Li M,et al.Resin pressure and resin flow inside tapered laminates during zero-bleeding and bleeding processes[J].Journal of Reinforced Plastics and Composites,2012,31(4):205-214.
[2]陈巍.先进航空发动机树脂基复合材料技术现状与发展趋势[J].航空制造技术,2016(5):68-72.
[3]Huang C K.Study on co-cured composite panels with blade-shaped stiffeners[J].Composites Part A-Applied Science and Manufacturing,2003,34(5):403-410.
[4]周源琦,蒲永伟,湛利华,等.复合材料帽型结构热压共固化成型质量研究[J].航空材料学报,2015(5):75-81.
[5]王莹,武彬彬,王浩军.复合材料“J”型加筋壁板成型工艺研究[J].粘接,2017(2):61-63.
[6]罗刚堂,李敏,顾轶卓,等.共胶接T型加筋壁板模具设计及成型工艺研究[J].玻璃钢/复合材料,2012(5):58-64.
[7]蒲永伟,刘沛禹,刘智,等.大尺寸工字型复合材料长桁整体成型工艺研究[C]//第17届全国复合材料学术会议.北京:2012.
[8]黄其忠,任明法,陈浩然.先进格栅增强复合材料结构在软模共固化成型过程中工艺参数研究[J].工程力学,2011(4):226-231.
[9]Fernlund G,Griffith J,Courdji R,et al.Experimental and numerical study of the effect of caul-sheets on corner thinning of composite laminates[J].Composites Part A-Applied Science and Manufacturing,2002,33(3):411-426.
[10]Xin C B,Gu Y Z,Li M,et al.Experimental and numerical study on the effect of rubber mold configuration on the compaction of composite angle laminates during autoclave processing[J].Composites Part a:Applied Science and Manufacturing,2011,42(10):1353-1360.
[11]Wang X,Xie F,Li M,et al.Influence of tool assembly schemes and integral molding technologies on compaction of T-stiffened skins in autoclave process[J].Journal of Reinforced Plastics and Composites,2010,29(9):1311-1322.
[12]谢富原,王雪明,李敏,等.T形加筋板热压罐成型过程压力分布与树脂流动实验研究[J].复合材料学报,2009,26(6):66-71.
[13]Kim G,Choi J,Kweon J.Manufacture and performance evaluation of the composite hat-stiffened panel[J].Composite Structures,2010,92(9SI):2276-2284.
[14]Li S,Pu Y,Zhan L,et al.Effect of mandrel structures on co-curing quality for polymer composite hat-stiffened structures[J].Fibers and Polymers,2015,16(9):1898-1907.
[15]扎姆阿茹娜,张佐光,王科,等.复合材料热压成型过程用光纤压力测试技术[J].复合材料学报,2004(1):45-50.
[16]王科,张佐光,扎姆阿茹娜,等.光纤微弯压力测试系统实时监测复合材料热压成型过程[J].复合材料学报,2005(2):67-70.
[17]李艳霞,顾轶卓,李敏,等.先进复合材料热压罐工艺成型过程压力监测技术[J].航空制造技术,2015(9):82-86.
[18]刘小龙,顾轶卓,李敏,等.采用薄膜传感器的树脂基复合材料热压罐工艺密实压力测试方法[J].复合材料学报,2013(5):67-73.
[19]顾轶卓,张佐光,李敏.复合材料热压成型过程的树脂压力测试系统[J].复合材料学报,2007(2):23-27.
[20]孙凯,李敏,顾轶卓,等.热压罐零吸胶工艺树脂压力在线测试及其变化规律[J].复合材料学报,2010(4):94-99.
[21]卢鑫,孙志杰,李超,等.硅橡胶热膨胀工艺预浸料铺层内树脂压力变化规律[J].复合材料学报,2011(3):50-55.
[22]辛朝波,徐吉峰,顾轶卓,等.热压罐工艺树脂压力测试系统适用性实验研究[J].复合材料学报,2013(5):74-78.
[23]Gutowski T G,Morigaki T,Zhong C.The consolidation of laminate composites[J].Journal of Composite Materials,1987,21(2):172-188.
[24]Wang X,Xie F,Li M,et al.Influence of core fillers on resin flow and fiber compaction of cocured skin-to-stiffener structures[J].Polymer Composites,2010,31(8):1360-1368.
[25]Wang X,Xie F,Li M,et al.Experimental investigation of the compaction and tensile strength of co-cured skin-to-stiffener structures[J].Applied Composite Materials,2011,18(5):371-383.
[26]Dave R.A unified approach to modeling resin flow during composite processing[J].Journal of Composite Materials,1990,24(1):22-41.
[27]Xin C,Gu Y,Li M,et al.Online monitoring and analysis of resin pressure inside composite laminate during zero-bleeding autoclave process[J].Polymer Composites,2011,32(2):314-323.
[28]Xin C,Li M,Gu Y,et al.Study on the resin flow and fiber compaction of tapered composite laminates during autoclave processing[J].Journal of Reinforced Plastics and Composites,2011,30(16):1399-1411.
[29]Gu Y,Xin C,Li M,et al.Resin pressure and resin flow inside tapered laminates during zero-bleeding and bleeding processes[J].Journal of Reinforced Plastics and Composites,2012,31(4):205-214.