碳纤维增强聚苯硫醚复合材料激光加热原位成型过程中的温度场
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摘要
连续纤维增强热塑性复合材料(Thermoplastic Composite,TPC)自动铺放(Automated Fiber Placement,AFP)可以实现铺层原位成型,因此在制造大型结构件、降低加工成本及提升生产效率方面潜力巨大。原位成型过程中铺层温度场分布对复合材料构件成型质量具有较大影响,且激光加热过程中又涉及激光能量场与预浸料吸收光能后产生的温度场之间相互耦联,机理复杂,因此结合传热模型,通过有限元模拟仿真研究激光辅助加热自动铺放成型连续碳纤维增强聚苯硫醚(CF/PPS)复合材料过程中铺层经历的温度历程。同时构建铺层温度场测量系统,对铺层经历的温度历程进行实时采集和存储。研究结果表明,铺放过程中黏合区域前方存在激光辐照阴影区,使压辊下方黏合区域的温度急剧下降;随着铺放速度的增加,黏合区域峰值温度逐渐降低,且成型速度越快,铺层间黏合区域峰值温度差越小,而热电偶测量结果与仿真结果相差越大;随着激光输出功率的增大,铺层峰值温度逐渐升高;为提高原位成型效率,当激光输出功率选择最大6kW时,最大铺放速度为0.75m/s。通过对比,试验结果中的峰值温度与仿真模拟结果变化趋势相近,证明了有限元仿真模型的正确性。
The automated fiber placement(AFP)of continuous fiber reinforced thermoplastic composite(TPC)could realize the in-situ consolidation and offer the potential to manufacture large components,reduce cost and increase production rate.Desired quality of composite components depends intensively on the temperature field distribution,and the laser heating mechanism is very complicated because of the laser energy field is coupled with the temperature field generated by the absorption of laser,so the temperature history for laser heating of carbon fiber reinforced polyphenyl sulphide(CF/PPS)matrix composite in an automated fiber placement process was studied in the finite element simulation combined heat transfer model.Meanwhile,the temperature field measurement system was built to collect and memory the temperature history for layers.The study results show that a shadow zone is present prior to the bond zone and causes a rapid drop in temperature.The peak temperature of the bond zone gradually decreases belong with the increasing of placing speed and the faster the placement speed is,the smaller the peak temperature difference is and the bigger the difference between thermocouple and simulation is.With the increase of the laser output power,the peak temperature of the layers increases gradually.To improve the efficiency of the insitu consolidation,the maximum speed is 0.75 m/s when the laser output power is 6 kW.Because of the trend issimilar by comparing peak temperature of the experimental results and the simulated results,the finite element simulation results are correct.
The automated fiber placement(AFP)of continuous fiber reinforced thermoplastic composite(TPC)could realize the in-situ consolidation and offer the potential to manufacture large components,reduce cost and increase production rate.Desired quality of composite components depends intensively on the temperature field distribution,and the laser heating mechanism is very complicated because of the laser energy field is coupled with the temperature field generated by the absorption of laser,so the temperature history for laser heating of carbon fiber reinforced polyphenyl sulphide(CF/PPS)matrix composite in an automated fiber placement process was studied in the finite element simulation combined heat transfer model.Meanwhile,the temperature field measurement system was built to collect and memory the temperature history for layers.The study results show that a shadow zone is present prior to the bond zone and causes a rapid drop in temperature.The peak temperature of the bond zone gradually decreases belong with the increasing of placing speed and the faster the placement speed is,the smaller the peak temperature difference is and the bigger the difference between thermocouple and simulation is.With the increase of the laser output power,the peak temperature of the layers increases gradually.To improve the efficiency of the insitu consolidation,the maximum speed is 0.75 m/s when the laser output power is 6 kW.Because of the trend issimilar by comparing peak temperature of the experimental results and the simulated results,the finite element simulation results are correct.
引文
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[18]李志猛,杨涛,杜宇,等.热塑性预浸丝铺放过程中温度场数学模型及其仿真[J].宇航材料工艺,2012,42(3):20-23.LI Z M,YANG T,DU Y,et al.Modeling and simulation of heat transfer in thermoplastic composite tow-placement process[J].Aerospace Materials&Technology,2012,42(3):20-23(in Chinese).
[19] LI Z M,YANG T,DU Y.Dynamic finite element simulation and transient temperature field analysis in thermoplastic composite tape lay-up process[J].Journal of Thermoplastic Composite Materials,2015,28(4):558-573.
[20]宋清华,肖军,文立伟,等.热塑性复合材料自动铺放过程中温度场研究[J].材料工程,2018,46(1):83-91.SONG Q H,XIAO J,WEN L W,et al.Temperature field during automated fiber placement for thermoplastic composite[J].Journal of Materials Engineering,2018,46(1):83-91(in Chinese).
[2]宋清华,肖军,文立伟,等.玻璃纤维增强热塑性塑料在航空航天领域中的应用[J].玻璃纤维,2012(6):40-43.SONG Q H,XIAO J,WEN L W,et al.Applications of glass fiber reinforced thermoplastics in aerospace sector[J].Fiber Glass,2012(6):40-43(in Chinese).
[3] VAIDYA U,李进松,管佳明.热塑性复合材料在航空航天中的应用[J].航空制造技术,2015,483(14):69-71.VAIDYA U,LI J S,GUAN J M.Thermoplastic composites for aerospace applications[J].Aeronautical Manufacturing Technology,2015,483(14):69-71(in Chinese).
[4]张婷.高性能热塑性复合材料在大型客机结构件上的应用[J].航空制造技术,2013,435(15):32-35.ZHANG T.Applications of high performance thermoplastic composites for commercial airplane structural component[J].Aeronautical Manufacturing Technology,2013,435(15):32-35(in Chinese).
[5]见雪珍,杨洋,袁协尧,等.商用客机连续纤维增强热塑性复合材料的现状及其发展趋势[J].上海塑料,2015(2):17-22.JIAN X Z,YANG Y,YUAN X Y,et al.Research on the development of welding technology of fiber reinforced thermoplastics in the aviation field[J].Shanghai Plastics,2015(2):17-22(in Chinese).
[6]张增焕,刘红兵.航空领域热塑性纤维复合材料焊接技术发展研究[J].航空制造技术,2015,483(14):72-75.ZHANG Z H,LIU H B.Research on the development of welding technology of fiber reinforced thermoplastics in the aviation field[J].Aeronautical Manufacturing Technology,2015,483(14):72-75(in Chinese).
[7]宋清华,肖军,文立伟,等.热塑性复合材料自动纤维铺放装备技术[J].复合材料学报,2016,33(6):1214-1222.SONG Q H,XIAO J,WEN L W,et al.Automated fiber placement system technology for thermoplastic composites[J].Acta Materiae Compositae Sinica,2016,33(6):1214-1222(in Chinese).
[8]富宏亚,李玥华.热塑性复合材料纤维铺放技术研究进展[J].航空制造技术,2012(18):44-48.FU H Y,LI Y H.Research on thermoplastic composites fiber placement technology[J].Aeronautical Manufacturing Technology,2012(18):44-48(in Chinese).
[9]迪力穆拉提·阿卜力孜,段玉岗,李涤尘,等.树脂基复合材料原位固化制造技术概述[J].材料工程,2011(10):84-90.ABLZ D L M L T,DUAN Y G,LI D C,et al.Overview of in-situ curing manufacturing technology for resin matrix composites[J].Journal of Materials Engineering,2011(10):84-90(in Chinese).
[10] QURESHI Z,SWAIT T,SCAIFE R,et al.In situ consolidation of thermoplastic prepreg tape using automated tape placement technology:Potential and possibilities[J].Composites Part B:Engineering,2014,66(11):255-267.
[11] BEYELER E,PHILLIPS W,GERI S I.Experimental investigation of laser-assisted thermoplastic tape consolidation[J].Journal of Thermoplastic Composite Material,1988,1(1):107-121.
[12] BINETRUY C,CLEMENT S,DELEGLISE M,et al.Gluefree assembly of glass fiber reinforced thermoplastics using laser light[J].SPIE Proceedings,2011,8065(2):1-7.
[13] MOSKVITIN G V,POLYAKOV A N,BIRGER E M.Laser welding of plastics(review)[J].Welding International,2013,27(9):725-734.
[14] GROVE S M.Thermal modeling of tape laying with continuous carbon fiber reinforced thermoplastic[J].Composites,1988,19(5):367-375.
[15] TURNKOR S,TURKMEN N,CHASSAPIS C,et al.Modeling of heat transfer in thermoplastic composite tape lay-up manufacturing[J].Heat Mass Transfer,2001,28(1):49-58.
[16] NOHA H,JOSEPH E T,BATRA R C,et al.A heat transfer analysis of the fiber placement composite manufacturing process[J].Journal of Reinforced Plastics and Composites,2005,24(8):869-887.
[17]李玥华.热塑性预浸丝变角度铺放及其轨迹规划的研究[D].哈尔滨:哈尔滨工业大学,2013.LI Y H.Research on thermoplastic towpreg variable angle placement and trajectory planning[D].Harbin:Harbin Institute of Technology,2013(in Chinese).
[18]李志猛,杨涛,杜宇,等.热塑性预浸丝铺放过程中温度场数学模型及其仿真[J].宇航材料工艺,2012,42(3):20-23.LI Z M,YANG T,DU Y,et al.Modeling and simulation of heat transfer in thermoplastic composite tow-placement process[J].Aerospace Materials&Technology,2012,42(3):20-23(in Chinese).
[19] LI Z M,YANG T,DU Y.Dynamic finite element simulation and transient temperature field analysis in thermoplastic composite tape lay-up process[J].Journal of Thermoplastic Composite Materials,2015,28(4):558-573.
[20]宋清华,肖军,文立伟,等.热塑性复合材料自动铺放过程中温度场研究[J].材料工程,2018,46(1):83-91.SONG Q H,XIAO J,WEN L W,et al.Temperature field during automated fiber placement for thermoplastic composite[J].Journal of Materials Engineering,2018,46(1):83-91(in Chinese).