石英纤维复合材料的磨削加工性能研究
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摘要
为了探究石英纤维复合材料在磨削过程中的损伤演变规律及磨削性能,本文将2.5维石英纤维机织复合材料作为研究对象,对材料各个组分分别建模构成细观几何模型.通过使用SolidWorks中二次开发中Rnd函数生成多个随机平面将磨粒切割成多面体,利用ABAQUS有限元分析软件首先对复合材料细观模型进行三维单磨粒磨削仿真,再分别从不同纤维方向进行基于三相微观结构的二维磨削仿真,分析了不同的纤维方向对加工表面质量的影响.通过进行磨削实验观察材料表面形貌,利用声发射技术对材料损伤实时监测并与仿真对比,结果表明复合材料断裂起始主要是由基体最大主应力和界面强度主导的,产生的裂纹沿着界面扩展,纤维束于不同磨削方向加工时由于受到磨粒剪切、弯曲、挤压及耕犁等不同的综合作用,断头呈不同的状态,纤维受剪切作用的加工表面质量比纤维受拉压发生断裂后的表面质量较好.
In this study,we developed a meso-geometric model by modeling each element of 2.5-dimensional woven composites to investigate the damage mechanism and grinding performance of composites. Using the secondary development function Rnd in SolidWorks,the abrasive grain can be cut into polyhedrons by multiple random planes.We simulated the single-abrasive grinding process in three-dimension using the finite element software ABAQUS. In addition,we performed a two-dimensional grinding simulation with different fiber angles in a three-phase microstructure;hence,we analyzed the surface qualities associated with different angles. We examined the surface morphology of materials after grinding via scanning electron microscopy(SEM),and monitored the material damage via real time acoustic emission technology. From the simulation,we determined the initiation of fractures to be dominated by the maximum principal stress of the matrix and the interfacial strength,with cracks expanding along the interface. Various shapes of the broken fibers are caused by different integrated impacts during the processing of fiber bundles in different grinding directions,such as shearing,bending,squeezing,and ploughing of abrasive grains. The surface quality of fibers subjected to shearing tends to be higher than those subjected to stretching and compression.
In this study,we developed a meso-geometric model by modeling each element of 2.5-dimensional woven composites to investigate the damage mechanism and grinding performance of composites. Using the secondary development function Rnd in SolidWorks,the abrasive grain can be cut into polyhedrons by multiple random planes.We simulated the single-abrasive grinding process in three-dimension using the finite element software ABAQUS. In addition,we performed a two-dimensional grinding simulation with different fiber angles in a three-phase microstructure;hence,we analyzed the surface qualities associated with different angles. We examined the surface morphology of materials after grinding via scanning electron microscopy(SEM),and monitored the material damage via real time acoustic emission technology. From the simulation,we determined the initiation of fractures to be dominated by the maximum principal stress of the matrix and the interfacial strength,with cracks expanding along the interface. Various shapes of the broken fibers are caused by different integrated impacts during the processing of fiber bundles in different grinding directions,such as shearing,bending,squeezing,and ploughing of abrasive grains. The surface quality of fibers subjected to shearing tends to be higher than those subjected to stretching and compression.
引文
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[17]冯古雨,曹海建,周红涛,等.三维机织复合材料单胞模型各向异性的有限元分析[J].玻璃钢/复合材料,2017(8):48-52.Feng Guyu,Cao Haijian,Zhou Hongtao,et al.Finite element analysis on anisotropy of 3D composite unit-cell model[J].Fiber Reinforced Plastic/Composites,2017(8):48-52(in Chinese).
[18]关天茹.2.5D编织石英/SiO2陶瓷基复合材料细观模型构建与实验验证[D].南京:南京航空航天大学,2012.Guan Tianru.Microgeometry and Mechanical Model and Experimental Study of 2.5D Braided Quartz/SiO2 Ceramic Matrix Composites[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2012(in Chinese).
[19]郭芳芳,肖建章.基于三相微观结构的纤维复合材料切削仿真研究[J].工具技术,2017,51(6):26-30.Guo Fangfang,Xiao Jianzhang.Study on cutting simulation of fiber reinforced composite materials based on three phase microstructure[J].Tool Engineering,2017,51(6):26-30(in Chinese).
[20]韩文钦.复合材料层合板损伤演化的实验和数值分析[D].镇江:江苏大学,2017.Han Wenqin.Experimental and Numerical Analysis on Damage Evolution of Composite Laminates[D].Zhenjiang:Jiangsu University,2017(in Chinese).
[2]董伟锋,张建钟,肖军.2.5D机织复合材料弹性性能的有限元分析[J].材料工程,2009(增2):9-14.Dong Weifeng,Zhang Jianzhong,Xiao Jun.Finite element analysis of the elastic properties of 2.5D woven composites[J].Journal of Materials Engineering,2009(Suppl 2):9-14(in Chinese).
[3]姚瑶,金利民.层层接结三维角联锁机织复合材料的三点弯曲疲劳破坏[J].纤维复合材料,2014(2):41-44.Yao Yao,Jin Limin.Fatigue damage of layer-to-layer three-dimensional angle-interlock woven composite undergoing three-point bending loading[J].Fiber Composites,2014(2):41-44(in Chinese).
[4]Ko F,Du G W.Processing of textile performs[C]//Advanced Composites Manufacturing.New York:New York John Wiley&Sons,Inc,1997:187-189.
[5]Pochiraju K,Chou T W.Three-dimensionally woven and braided composites-1:A model for anisotropic stiffness prediction[J].Polymer Composites,1999,20(4):565-580.
[6]Wang Yuguo,Ding Chao,Lin Bin.FEM simulation of single-grit grinding on a 2.5D woven composite[J].Transactions of Tianjin University,2017,23(1):1-9.
[7]路冬,李志凯,融亦鸣,等.基于宏观各向异性碳纤维增强树脂基复合材料的切削仿真[J].复合材料学报,2014,31(3):584-590.Lu Dong,Li Zhikai,Rong Yiming,et al.Cutting simulation of carbon fiber reinforced resin matrix composite material based on macroscopic anisotropy[J].Acta Materiae Compositae Sinica,2014,31(3):584-590(in Chinese).
[8]高汉卿,贾振元,王福吉,等.基于细观仿真建模的CFRP细观破坏[J].复合材料学报,2016,33(4):758-767.Gao Hanqing,Jia Zhenyuan,Wang Fuji,et al.Mesoscopic failure of CFRP based on mesoscopic simulation modeling[J].Acta Materiae Compositae Sinica,2016,33(4):758-767(in Chinese).
[9]Abena A,Soo S L,Essa K.Modelling the orthogonal cutting of UD-CFRP composites:Development of a novel cohesive zone model[J].Composite Structures,2017,168:65-83.
[10]Solani X,Santinuste C.Influence of tool geometry and numerical parameters when modeling orthogonal cutting of LERP composites[J].Composites,2011,42:1205-1216.
[11]Rao G,Mahajan P,Bhatnagar N.Three-dimensional macro-mechanical finite element model for machining of unidirectional-fiber reinforced polymer composites[J].Materials Science and Engineering A,2008,498:142-149.
[12]Mahdi M,Zhang L C.An adaptive three dimensional finite element algorithm for the orthogonal cutting of composite materials[J].Journal of Materials Processing Technology,2001,113(1):368-372.
[13]李巾锭,任成祖,吕哲,等.单颗粒金刚石平面磨削C/SiC复合材料的有限元仿真[J].材料科学与工程学报,2014,32(5):686-689.Li Jinding,Ren Chengzu,LüZe,et al.Finite element simulation of single diamond abrasive surface grinding C/SiC[J].Journal of Materials Science&Engineering,2014,32(5):686-689(in Chinese).
[14]Woo Sung-Choong,Kim Tae-Won.High strain-rate failure in carbon/Kevlar hybrid woven composites via a novel SHPB-AE coupled test[J].Composites Part B,2016,97:317-328.
[15]Ely T M,Hill E.Longitudinal splitting and fiber breakage characterization in graphite epoxy using acoustic emission data[J].Materials Evaluation,1995,53(2):288-294.
[16]Gutkin R,Green C J,Vangrattanachai S,et al.On acoustic emission for failure investigation in CFRP:Pattern recognition and peak frequency analyses[J].Mechanical System and Signal Processing,2011,25(4):1393-1407.
[17]冯古雨,曹海建,周红涛,等.三维机织复合材料单胞模型各向异性的有限元分析[J].玻璃钢/复合材料,2017(8):48-52.Feng Guyu,Cao Haijian,Zhou Hongtao,et al.Finite element analysis on anisotropy of 3D composite unit-cell model[J].Fiber Reinforced Plastic/Composites,2017(8):48-52(in Chinese).
[18]关天茹.2.5D编织石英/SiO2陶瓷基复合材料细观模型构建与实验验证[D].南京:南京航空航天大学,2012.Guan Tianru.Microgeometry and Mechanical Model and Experimental Study of 2.5D Braided Quartz/SiO2 Ceramic Matrix Composites[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2012(in Chinese).
[19]郭芳芳,肖建章.基于三相微观结构的纤维复合材料切削仿真研究[J].工具技术,2017,51(6):26-30.Guo Fangfang,Xiao Jianzhang.Study on cutting simulation of fiber reinforced composite materials based on three phase microstructure[J].Tool Engineering,2017,51(6):26-30(in Chinese).
[20]韩文钦.复合材料层合板损伤演化的实验和数值分析[D].镇江:江苏大学,2017.Han Wenqin.Experimental and Numerical Analysis on Damage Evolution of Composite Laminates[D].Zhenjiang:Jiangsu University,2017(in Chinese).