T型整体壁板制件RFI工艺与性能的研究
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摘要
本文采用高性能碳(玻璃)纤维2D增强机织物，利用增粘纺织预成型技术，开发出了适用于民用客机尾翼整体蒙皮用叠层预制件。设计了适用于树脂膜熔渗工艺(RFI—Resin Film Infusion)的模具和剪切实验用夹具，对增粘叠层预制件压缩性能、渗透性能及RFI工艺一维树脂流动模型进行了理论和试验研究，研制出适合本课题用高性能环氧树脂膜，通过优化设计树脂膜熔渗工艺(RFI)，制造了T型整体壁板蒙皮复合材料制件。
树脂传递模塑(RTM—Resin Transfer Molding)工艺存在加工尺寸的技术限制，热压罐袋压成型工艺(BMPA—Bag Molding Process for Autoclave)一般仅能有效加工单向带和2D预浸料，树脂膜熔渗工艺(RFI)突破了加工尺寸和预制件型式的限制，其工艺过程简单、成型压力低、制造成本低，适宜制造大型板类、壳类复合材料制件，在航空和船舶航空、船舶及建筑等行业具有广泛的应用前途。
本文对增粘缝纫叠层预制件(增粘处理方法、增粘处理工艺)和高性能环氧树脂膜(树脂膜配方、树脂膜加工工艺和树脂膜性能测试方法)的研制过程、树脂膜融渗(RFI)工艺设计方法、RFI一维流动模型、RFI工艺模具和剪切实验用夹具的设计研究进行了详细地分析论述，其技术工艺和理论成果可直接应用制造领域。
根据技术性能的要求，对T型整体壁板蒙皮制件进行树脂浸润质量检测和剪切屈曲实验，测试结果表明T型整体壁板孔隙含量较低，其临界屈曲强度、破坏强度及破坏模式均达到设计要求。
In this dissertation, tackified laminate performs manufactured by tackified textile performing technology and high performance carbon fiber (glass fiber) 2D woven fabric have been developed, it will be used on tail integrated panel of civil plane. The consolidation and permeability characterization of tackified laminate performs, and one dimensional RFI resin flow modeling was fully discussed with test methods. Toolings suitable for the Resin Film Infusion (RFI) process and shear test rig have been designed. By developing epoxy resin film and optimizing technical data of resin film infusion (RFI), several T integrated panels were successfully produced.
There are some technical limitations in manufacturing super size composites with Resin Transfer Molding Process (RTM), generally speaking Bag Molding Process for Autoclave can efficiently process unidirectional and 2D prepreg, but Resin Film Infusion process can be used to manufacture panel and shell with ultra size. It has following advantages such as simple technological process, low pressure and cost. In the near future, RFI process will be extensively utilized in aviation, shipping and building industry.
This paper studies the manufacturing process of tackified stitching laminate performs (tackified method and technology) and epoxy resin film with high property ( formulation, manufacturing technology and performance test methods of resin film), and analyses the design method of Resin film infusion technology, RFI one dimensional resin flow modeling , RFI toolings and test rig, these technical data and theoretical results can be transferred to the industry fields.
The resin infusion test results show the T integrated panels has very low void content, shear buckling test demonstrates that the critical bucking load, failure load and failure mode of T integrated panels (stitched and unstitched) are over the technical requirements.
树脂传递模塑(RTM—Resin Transfer Molding)工艺存在加工尺寸的技术限制，热压罐袋压成型工艺(BMPA—Bag Molding Process for Autoclave)一般仅能有效加工单向带和2D预浸料，树脂膜熔渗工艺(RFI)突破了加工尺寸和预制件型式的限制，其工艺过程简单、成型压力低、制造成本低，适宜制造大型板类、壳类复合材料制件，在航空和船舶航空、船舶及建筑等行业具有广泛的应用前途。
本文对增粘缝纫叠层预制件(增粘处理方法、增粘处理工艺)和高性能环氧树脂膜(树脂膜配方、树脂膜加工工艺和树脂膜性能测试方法)的研制过程、树脂膜融渗(RFI)工艺设计方法、RFI一维流动模型、RFI工艺模具和剪切实验用夹具的设计研究进行了详细地分析论述，其技术工艺和理论成果可直接应用制造领域。
根据技术性能的要求，对T型整体壁板蒙皮制件进行树脂浸润质量检测和剪切屈曲实验，测试结果表明T型整体壁板孔隙含量较低，其临界屈曲强度、破坏强度及破坏模式均达到设计要求。
In this dissertation, tackified laminate performs manufactured by tackified textile performing technology and high performance carbon fiber (glass fiber) 2D woven fabric have been developed, it will be used on tail integrated panel of civil plane. The consolidation and permeability characterization of tackified laminate performs, and one dimensional RFI resin flow modeling was fully discussed with test methods. Toolings suitable for the Resin Film Infusion (RFI) process and shear test rig have been designed. By developing epoxy resin film and optimizing technical data of resin film infusion (RFI), several T integrated panels were successfully produced.
There are some technical limitations in manufacturing super size composites with Resin Transfer Molding Process (RTM), generally speaking Bag Molding Process for Autoclave can efficiently process unidirectional and 2D prepreg, but Resin Film Infusion process can be used to manufacture panel and shell with ultra size. It has following advantages such as simple technological process, low pressure and cost. In the near future, RFI process will be extensively utilized in aviation, shipping and building industry.
This paper studies the manufacturing process of tackified stitching laminate performs (tackified method and technology) and epoxy resin film with high property ( formulation, manufacturing technology and performance test methods of resin film), and analyses the design method of Resin film infusion technology, RFI one dimensional resin flow modeling , RFI toolings and test rig, these technical data and theoretical results can be transferred to the industry fields.
The resin infusion test results show the T integrated panels has very low void content, shear buckling test demonstrates that the critical bucking load, failure load and failure mode of T integrated panels (stitched and unstitched) are over the technical requirements.
引文
1 Scott W. Beckwith and Craig R. Hyland. Resin Transfer molding : a decade of technology advances, SAMPE Journal, 1998, Vo134, No.6, 7-19
2 A. Hammami and B.R. Gebbart. Analysis of the Vacuum Infusion Molding Process, Polymer composites, February 2000, vol.21, No. 1, 28-40
3 Christopher Williams, John Stalest and Stephen Grove, Resin Infusion under flexible Tooling(RIFT): a review, Composites :Part A 27A (1996) 517-524
4 Coulter JP, Guceri SI. Resin impregnation during the manufacturing of composite materials subject to prescribed injection rate. Journal of Reinforced Plastics and Composites, 1988, 7(5), 200-219
5 C. Lekakou, M.A.K.Johari, D.norman and M.G.Bader. Measurement techniques and effects on in-plane permeability of woven cloths in resin transfer moulding, composites: Part A 27A (1996) 401-408
6 王东、梁国正，“用于RFI工艺的高性能树脂膜的研究”，复合材料学报，Vol．18 No．1 Feb．2001
7 Product Data Sheet of M18 Manufactured by Hexcel Composites.
8 Product Data Sheet of HexPly M36 Manufactured by Hexcel Composites
9 Product Data Sheet of XHTM45 Manufactured by Advanced Composites Group.
10 Krusche T, Michaeli W. Resin infusion technology for the autoclave process, Int SAMPE Symp & Exhibition, 1996, 41(2): 1542-1550.
11 Hiroshi Uchida, Takumi Yamamoto, Hiroki Takashima, Development of Low-Cost, Damage Resistant Composites Using RFI Processing, SAMPE Journal, Vol.37, No.6, P16-20, November/December 2001
12 ALFRED C. LOOS, Low-cost fabrication of advanced polymeric composites by resin infusion processes, Advanced Composites Material., Vol. 10, No.2,3, PP99-106.
13 R.W. Hillermeier, Brian S. Hayes and James C. Seffeeris, "Tackifier/Binder Toughened Resin Transfer Molding Composites", Journal of Advanced Materials, Volume 32, No.3, July 2000, P27-34
14 A.C.CABA, et, al., Verification of a simulation model for resin film infusion of complex shaped composite structures, Journal of Reinforced Plastics and Composites, 1999, Vol. 18, No. 16
15 Alfred C. Loos and john D. Macrae. A process simulation model for the manufacture of a blade -stiffened panel by the resin film infusion process, Composites Science and Technology, 1996, 56, 273-289
16 http://www.airkiller.myrice.com/fighter.htm
17 陶梅贞．现代飞机结构综合设计．西北工业大学出版社，2000．
18 龚尧南．结构力学．北京航空航天大学出版社，2001
19 Teresa M. Kruckenberg et, Resin Transfer Moulding for Aerospace Structures, Kluwer Academic Publishers．DORDRECHT/BOSTON/LONDON
20 Rchatgi. V. and Lee. L. J., Moldability of Tackified fibre Preforms in Liquid composite Moulding,
Journal of Composites Materials, 31,720-44, 1997
21 Product Data Sheet of 3M PT 500 Powder Tackifier Manufactured by 3M.
22 Z.Cai and T. Gutowski, " The 3-D Deformation Behavior of a Lubricated fiber Bundle", Journal of composites Materials, Vol. 26, No.8, 1992, P1207-1226.
23 Staffan Toll, " Packing Mechanics of Fiber Reinforcements", Polymer Engineering and Science, Vol. 38, No.8, 1998, P1337-1350
24 Colan Products PTY. Limited, "Technical Data Sheet", 1996.
25 Toray Industries, Inc. "Quality Carbon Fiber Technical Data", 1992.
26 M.V. Bruschke and S.G. Advani. A Finite Element/control Volume Approach to Molding Filling in Anisotropic Porous Media, Polymer Composites, December 1990, vol. 11, No.6, 398-404
27 Ghiorse S.R., "Effect of Void content on The Mechanical Properties of Carbon/Epoxy Laminates", SAMPE Q., 24(2), P54-59, 1993
28 Bowies K.J. & Frimpong SJ, "Void Effects on the Interlaminar Shear Strength of Unidirectional Graphite Fiber Reinforced Composites," Composite Material., 26(10), P1487-1509, 1992
29 Richard S. Parnas, et al., " A permeability Database for Composites Manufacturing", Polymer Composites, Oct., 1997, vol. 18, No. 5, 623-633
30 Kurt L. Adams, et al., "Forced In-Plane Flow of an Epoxy Resin in Fibrous Networks", Polymer Engineering and Science, 1986, Vol. 26, No.20, 1434-1441
31 Albert W. Chan and Sun-Tak Hwang, "Anisotropic In-Plane Permeability of Fabric Media", Polymer Engineering and Science, August 1991, Vol. 31, No.16, 1233-1249
32 R. Gauvin. F. et al., "Permeability Measurement and Flow Simulation Through Fiber Reinforcement", Polymer Composites, February 1996, Vol. 17, No. 1, 34-42
33 W.-B. Young and S. F. Wu, " Peameability Measurement of Bidirectional Woven Glass Fibers," Journal of Reinforced Plastics and Composites, Vol. 14, Oct, P 1109-1110, 1995
34 Internalitional standards Organization. (1988). ISO Standards Handbook for Metal Materials, International Standards Organization, Geneva.
35 董秀石 魏玉霖主编，材料力学，机械工业出版社，1994．7
36 J.H.Postane "Plastic mould " , Oxford University Press,1978
37 F.R.Shanley, "Mechanics of Materials", McGraw-Hill Book Company,1967
38 Herbert Rees "Moulding Engineering" , Munic; New York, Hanser Publishers, 1995
39 Technical Data Sheet of ASSAB 618.
40 Product Data Sheet of 3501-6 Manufactured by Hexcel
41 Product Data Sheet of RTM6 Manufactured by Hexcel
42 Product Data Sheet of GY6010, HT907 and DY062 Manufactured by CIBA Composites.
43 ASTM Test Method D 638, "Standard Test Method for Tensile Properties of Plastics", Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA.
44 ASTM D 790, "Standard Test Methods for Flexural Properties of Unreinforced and Rein-forced Plastics and Electrical Insulating Materials," Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA.
45 ASTM D 695, "Standard Test Method for Compressive Properties of Rigid Plastics," Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA
46 S.T. Peters. "Handbook of Composites", Chapman & Hall, London. 1996
47 ASTM Test Method D 2393, "Viscosity of Epoxy Resins and Related Components," Annual k of ASTM Standards, Vol 8.02, American Society for Testing and Materials, West Conshohocken, PA.
48 ASTM Test Method D-2471 , "Gel Time of Resins and Related Components," Annual Book of ASTM Standards, Vol 8.02, American Society for Testing and Materials, West Conshohocken, PA
49 Richard B. Heslehurst, The Cure Pressure and Temperature Profiles, Advanced Composites'93, International conference on Advanced Composite Materials, P495-502
50 Product Data Sheet of American Autoclave Co. 1992.
51 Product Data Sheet of Ciba Geigy Polymers Division-Matrix Systems, Publ.No.24668/2/e, Sep 1991.
52 裘宗燕，Mathematica 数学软件系统的应用及其程序设计，北京大学出版社，1994
53 ACI Fibreglass Company Handbook, Design Data Handbook for Fibreglass Composites, 1988
54 章本照编著，流体力学中的有限元方法，机械工业出版社，1986，P371-374
55 周光垌、严宗毅、许世雄、章克本编著，流体力学，P50-55，P118-123，高等教育出版社，2000．6
56 孔祥言编著，高等渗流力学，P31-37，中国科学技术出版社，1999．7
57 Ghiorse S. R., "Effect of Void content on the Mechanical Properties of Carbon/Epoxy Laminates," SAMPE Q., 24(2), P54-59, 1993
58 Bowies K.J. & Frimpong S. J, "Void Effects on the Inter—laminar Shear Strength of Unidirectional Graphite Fiber Reinforced Composites," Composite Material., 26 (10), P 1487-1509, 1992
59 Jian-Liang Lin and Wen-Bin Young, " The effect of Preheater on the Resin Transfer Molding," Journal of Reinforced Plastics and Composites, Vol. 18, No. 10, P955-957,1999
60 ASTM D2734 "Standard Test Method for Void Content of Reinforced Plastics," Annual Book of ASTM Standards, ASTM, West Conshohocken, PA.
61 国家标准局，GB 3365-82，碳纤维增强塑料空隙含量检测方法。
62 ASTM D3518-76" Standard Test Method for Shear Properties of Reinforced Plastics, "Annual Book of ASTM Standards, ASTM, West Conshohocken, PA.
2 A. Hammami and B.R. Gebbart. Analysis of the Vacuum Infusion Molding Process, Polymer composites, February 2000, vol.21, No. 1, 28-40
3 Christopher Williams, John Stalest and Stephen Grove, Resin Infusion under flexible Tooling(RIFT): a review, Composites :Part A 27A (1996) 517-524
4 Coulter JP, Guceri SI. Resin impregnation during the manufacturing of composite materials subject to prescribed injection rate. Journal of Reinforced Plastics and Composites, 1988, 7(5), 200-219
5 C. Lekakou, M.A.K.Johari, D.norman and M.G.Bader. Measurement techniques and effects on in-plane permeability of woven cloths in resin transfer moulding, composites: Part A 27A (1996) 401-408
6 王东、梁国正，“用于RFI工艺的高性能树脂膜的研究”，复合材料学报，Vol．18 No．1 Feb．2001
7 Product Data Sheet of M18 Manufactured by Hexcel Composites.
8 Product Data Sheet of HexPly M36 Manufactured by Hexcel Composites
9 Product Data Sheet of XHTM45 Manufactured by Advanced Composites Group.
10 Krusche T, Michaeli W. Resin infusion technology for the autoclave process, Int SAMPE Symp & Exhibition, 1996, 41(2): 1542-1550.
11 Hiroshi Uchida, Takumi Yamamoto, Hiroki Takashima, Development of Low-Cost, Damage Resistant Composites Using RFI Processing, SAMPE Journal, Vol.37, No.6, P16-20, November/December 2001
12 ALFRED C. LOOS, Low-cost fabrication of advanced polymeric composites by resin infusion processes, Advanced Composites Material., Vol. 10, No.2,3, PP99-106.
13 R.W. Hillermeier, Brian S. Hayes and James C. Seffeeris, "Tackifier/Binder Toughened Resin Transfer Molding Composites", Journal of Advanced Materials, Volume 32, No.3, July 2000, P27-34
14 A.C.CABA, et, al., Verification of a simulation model for resin film infusion of complex shaped composite structures, Journal of Reinforced Plastics and Composites, 1999, Vol. 18, No. 16
15 Alfred C. Loos and john D. Macrae. A process simulation model for the manufacture of a blade -stiffened panel by the resin film infusion process, Composites Science and Technology, 1996, 56, 273-289
16 http://www.airkiller.myrice.com/fighter.htm
17 陶梅贞．现代飞机结构综合设计．西北工业大学出版社，2000．
18 龚尧南．结构力学．北京航空航天大学出版社，2001
19 Teresa M. Kruckenberg et, Resin Transfer Moulding for Aerospace Structures, Kluwer Academic Publishers．DORDRECHT/BOSTON/LONDON
20 Rchatgi. V. and Lee. L. J., Moldability of Tackified fibre Preforms in Liquid composite Moulding,
Journal of Composites Materials, 31,720-44, 1997
21 Product Data Sheet of 3M PT 500 Powder Tackifier Manufactured by 3M.
22 Z.Cai and T. Gutowski, " The 3-D Deformation Behavior of a Lubricated fiber Bundle", Journal of composites Materials, Vol. 26, No.8, 1992, P1207-1226.
23 Staffan Toll, " Packing Mechanics of Fiber Reinforcements", Polymer Engineering and Science, Vol. 38, No.8, 1998, P1337-1350
24 Colan Products PTY. Limited, "Technical Data Sheet", 1996.
25 Toray Industries, Inc. "Quality Carbon Fiber Technical Data", 1992.
26 M.V. Bruschke and S.G. Advani. A Finite Element/control Volume Approach to Molding Filling in Anisotropic Porous Media, Polymer Composites, December 1990, vol. 11, No.6, 398-404
27 Ghiorse S.R., "Effect of Void content on The Mechanical Properties of Carbon/Epoxy Laminates", SAMPE Q., 24(2), P54-59, 1993
28 Bowies K.J. & Frimpong SJ, "Void Effects on the Interlaminar Shear Strength of Unidirectional Graphite Fiber Reinforced Composites," Composite Material., 26(10), P1487-1509, 1992
29 Richard S. Parnas, et al., " A permeability Database for Composites Manufacturing", Polymer Composites, Oct., 1997, vol. 18, No. 5, 623-633
30 Kurt L. Adams, et al., "Forced In-Plane Flow of an Epoxy Resin in Fibrous Networks", Polymer Engineering and Science, 1986, Vol. 26, No.20, 1434-1441
31 Albert W. Chan and Sun-Tak Hwang, "Anisotropic In-Plane Permeability of Fabric Media", Polymer Engineering and Science, August 1991, Vol. 31, No.16, 1233-1249
32 R. Gauvin. F. et al., "Permeability Measurement and Flow Simulation Through Fiber Reinforcement", Polymer Composites, February 1996, Vol. 17, No. 1, 34-42
33 W.-B. Young and S. F. Wu, " Peameability Measurement of Bidirectional Woven Glass Fibers," Journal of Reinforced Plastics and Composites, Vol. 14, Oct, P 1109-1110, 1995
34 Internalitional standards Organization. (1988). ISO Standards Handbook for Metal Materials, International Standards Organization, Geneva.
35 董秀石 魏玉霖主编，材料力学，机械工业出版社，1994．7
36 J.H.Postane "Plastic mould " , Oxford University Press,1978
37 F.R.Shanley, "Mechanics of Materials", McGraw-Hill Book Company,1967
38 Herbert Rees "Moulding Engineering" , Munic; New York, Hanser Publishers, 1995
39 Technical Data Sheet of ASSAB 618.
40 Product Data Sheet of 3501-6 Manufactured by Hexcel
41 Product Data Sheet of RTM6 Manufactured by Hexcel
42 Product Data Sheet of GY6010, HT907 and DY062 Manufactured by CIBA Composites.
43 ASTM Test Method D 638, "Standard Test Method for Tensile Properties of Plastics", Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA.
44 ASTM D 790, "Standard Test Methods for Flexural Properties of Unreinforced and Rein-forced Plastics and Electrical Insulating Materials," Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA.
45 ASTM D 695, "Standard Test Method for Compressive Properties of Rigid Plastics," Annual Book of ASTM Standards, Vol 8.01, American Society for Testing and Materials, West Conshohocken, PA
46 S.T. Peters. "Handbook of Composites", Chapman & Hall, London. 1996
47 ASTM Test Method D 2393, "Viscosity of Epoxy Resins and Related Components," Annual k of ASTM Standards, Vol 8.02, American Society for Testing and Materials, West Conshohocken, PA.
48 ASTM Test Method D-2471 , "Gel Time of Resins and Related Components," Annual Book of ASTM Standards, Vol 8.02, American Society for Testing and Materials, West Conshohocken, PA
49 Richard B. Heslehurst, The Cure Pressure and Temperature Profiles, Advanced Composites'93, International conference on Advanced Composite Materials, P495-502
50 Product Data Sheet of American Autoclave Co. 1992.
51 Product Data Sheet of Ciba Geigy Polymers Division-Matrix Systems, Publ.No.24668/2/e, Sep 1991.
52 裘宗燕，Mathematica 数学软件系统的应用及其程序设计，北京大学出版社，1994
53 ACI Fibreglass Company Handbook, Design Data Handbook for Fibreglass Composites, 1988
54 章本照编著，流体力学中的有限元方法，机械工业出版社，1986，P371-374
55 周光垌、严宗毅、许世雄、章克本编著，流体力学，P50-55，P118-123，高等教育出版社，2000．6
56 孔祥言编著，高等渗流力学，P31-37，中国科学技术出版社，1999．7
57 Ghiorse S. R., "Effect of Void content on the Mechanical Properties of Carbon/Epoxy Laminates," SAMPE Q., 24(2), P54-59, 1993
58 Bowies K.J. & Frimpong S. J, "Void Effects on the Inter—laminar Shear Strength of Unidirectional Graphite Fiber Reinforced Composites," Composite Material., 26 (10), P 1487-1509, 1992
59 Jian-Liang Lin and Wen-Bin Young, " The effect of Preheater on the Resin Transfer Molding," Journal of Reinforced Plastics and Composites, Vol. 18, No. 10, P955-957,1999
60 ASTM D2734 "Standard Test Method for Void Content of Reinforced Plastics," Annual Book of ASTM Standards, ASTM, West Conshohocken, PA.
61 国家标准局，GB 3365-82，碳纤维增强塑料空隙含量检测方法。
62 ASTM D3518-76" Standard Test Method for Shear Properties of Reinforced Plastics, "Annual Book of ASTM Standards, ASTM, West Conshohocken, PA.