平针缝纫非织造布复合材料面内力学性能的研究
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摘要
从20世纪80年代初以来,将缝纫工艺用于制造先进3D复合材料已经取得了令人瞩目的成功。与传统的复合材料层合板相比,缝纫工艺大大提高了复合材料的分层阻抗和冲击损伤容限。同时,其生产成本比三维机织或编织复合材料低得多。但是,缝纫技术在提高复合材料层间性能的同时,面内性能由于缝纫造成的纤维破损、纤维错位、纤维弯折等原因而下降。因此,对缝纫复合材料面内力学性能进行研究就显得非常重要。基于此,本文主要开展了以下工作：
选用非织造布作为铺层材料,预制件由四层Kevlar纤维毡经过缝纫制得。缝纫采用了2种不同细度和品种的缝纫线、5种缝纫密度和2种缝纫方式,用真空辅助树脂传递模塑成型(VARTM)对缝纫后的预制件注入乙烯基酯树脂。经固化试验后,将复合材料板切割成拉伸或弯曲测试试样的尺寸。
在进行拉伸性能测试的时候,试样分别采用改进锁式和平针缝纫方式,以相同的缝纫密度、相同的缝纫线进行缝纫。与改进锁式方式缝纫的复合材料相比,平针缝纫复合材料试样的拉伸强度提高了7%,拉伸弹性模量提高了2.5%,弯曲强度提高了30.58%,弯曲模量提高了13.8%,证明了平针缝纫作为一种新的缝纫方式的发展潜力。
论文还研究了平针复合材料的缝纫密度、缝纫针距和行距、缝纫线的种类、缝纫线的细度等缝纫参数对复合材料弯曲性能的影响。研究结果表明,缝纫密度越大,缝纫复合材料的弯曲性能下降的越多；在缝纫密度相同的情况下,缝纫的行距比针距对弯曲性能的影响大；缝纫线的直径越大,缝纫后复合材料的弯曲性能的下降越多；而缝纫线种类对弯曲性能影响不大。
采用有限元分析软件ANSYS对非缝纫和缝纫复合材料的拉伸、弯曲过程进行了模拟,比较了非缝纫和缝纫复合材料试样的的面内应力和位移分布特点,从多方面阐述了缝纫复合材料拉伸弯曲性能降低的原因。
最后,通过总结本课题的不足之处,对平针缝纫设备、非织造布复合材料、缝纫复合材料全方面的力学性能测试等方面提出了展望。
Since the early 1980's, the stitching technology which was applied to manufacturing 3D composites has achieved great success. Compared with the traditional composite laminates,through-the-thickness stitching can effectively enhance the interlaminar fracture toughness and impact damage tolerance. Meanwhile, the production cost of the stitched composites is much lower than that of 3D woven or braid composites.However,while the interlaminar properties are largely improved, the in-plane properties are damaged due to the breakage, misalignment and kinking of the in-plane fibers.The research on the in-plane properties of stitched composites is becoming more and more important.Based on this, this paper carried out the following work:
In the experiments, non-woven fabrics were used as layer, materials, and 4 layers of Kevlar mats were stitched together into a preform. During the process of stitching, we selected 2 sewing yarns,5 stitching densities and 2 stitch patterns and then injected vinyl ester resin into the stitched structure by using Vacuum Assist Resin Transfer Molding (VARTM) technology. After composites were finished, the cured composites planes were cut into the sizes of tensile or bending property test specimen.
The specimen for tensile property tests were stitched with the modified locked stitch pattern and the plain stitch pattern respectively. We kept the stitching density and sewing yarn parameters invariable. Compared with composites stitched by the modified locked stitch pattern, the tensile strength of the composites stitched by plain stitch pattern increased by about 7%.The tensile elastic modulus was improved by 2.5%.The bending strength was raised by 30.58%,and the bending modulus was enhanced by 13.8%.The plain stitch pattern as a new stitch pattern was proven to be a potential one.
The effects of stitching parameters on the bending properties of composites stitched by the plain stitch pattern were investigated. The stitching parameters included stitching density, the stitch pitch distance, the stitch line spacing, the sewing yarn materials and the yarn fineness.lt was revealed that the higher the stitching density was, the more the bending property was damaged. The bigger the sewing yarn diameter was, the lower the bending strength was. What's more, when the stitching densities were identical, the stitch line spacing was much more influential than the stitch pitch distance. However, the sewing yarn materials almost had no effect on the bending properties.
The finite element analysis software was used to modal the process of the stretching and bending. The contour plots of stitched composites were compared with those of unstitched ones. By this way, the reason why the tensile and bending properties of stitched composites decreased was explained. At last,considering the deficiencies of this research, we came up with some prospects about the equipment for plain stitching, the non-woven fabric composites and a number of data from various properties of stitched composites.
选用非织造布作为铺层材料,预制件由四层Kevlar纤维毡经过缝纫制得。缝纫采用了2种不同细度和品种的缝纫线、5种缝纫密度和2种缝纫方式,用真空辅助树脂传递模塑成型(VARTM)对缝纫后的预制件注入乙烯基酯树脂。经固化试验后,将复合材料板切割成拉伸或弯曲测试试样的尺寸。
在进行拉伸性能测试的时候,试样分别采用改进锁式和平针缝纫方式,以相同的缝纫密度、相同的缝纫线进行缝纫。与改进锁式方式缝纫的复合材料相比,平针缝纫复合材料试样的拉伸强度提高了7%,拉伸弹性模量提高了2.5%,弯曲强度提高了30.58%,弯曲模量提高了13.8%,证明了平针缝纫作为一种新的缝纫方式的发展潜力。
论文还研究了平针复合材料的缝纫密度、缝纫针距和行距、缝纫线的种类、缝纫线的细度等缝纫参数对复合材料弯曲性能的影响。研究结果表明,缝纫密度越大,缝纫复合材料的弯曲性能下降的越多；在缝纫密度相同的情况下,缝纫的行距比针距对弯曲性能的影响大；缝纫线的直径越大,缝纫后复合材料的弯曲性能的下降越多；而缝纫线种类对弯曲性能影响不大。
采用有限元分析软件ANSYS对非缝纫和缝纫复合材料的拉伸、弯曲过程进行了模拟,比较了非缝纫和缝纫复合材料试样的的面内应力和位移分布特点,从多方面阐述了缝纫复合材料拉伸弯曲性能降低的原因。
最后,通过总结本课题的不足之处,对平针缝纫设备、非织造布复合材料、缝纫复合材料全方面的力学性能测试等方面提出了展望。
Since the early 1980's, the stitching technology which was applied to manufacturing 3D composites has achieved great success. Compared with the traditional composite laminates,through-the-thickness stitching can effectively enhance the interlaminar fracture toughness and impact damage tolerance. Meanwhile, the production cost of the stitched composites is much lower than that of 3D woven or braid composites.However,while the interlaminar properties are largely improved, the in-plane properties are damaged due to the breakage, misalignment and kinking of the in-plane fibers.The research on the in-plane properties of stitched composites is becoming more and more important.Based on this, this paper carried out the following work:
In the experiments, non-woven fabrics were used as layer, materials, and 4 layers of Kevlar mats were stitched together into a preform. During the process of stitching, we selected 2 sewing yarns,5 stitching densities and 2 stitch patterns and then injected vinyl ester resin into the stitched structure by using Vacuum Assist Resin Transfer Molding (VARTM) technology. After composites were finished, the cured composites planes were cut into the sizes of tensile or bending property test specimen.
The specimen for tensile property tests were stitched with the modified locked stitch pattern and the plain stitch pattern respectively. We kept the stitching density and sewing yarn parameters invariable. Compared with composites stitched by the modified locked stitch pattern, the tensile strength of the composites stitched by plain stitch pattern increased by about 7%.The tensile elastic modulus was improved by 2.5%.The bending strength was raised by 30.58%,and the bending modulus was enhanced by 13.8%.The plain stitch pattern as a new stitch pattern was proven to be a potential one.
The effects of stitching parameters on the bending properties of composites stitched by the plain stitch pattern were investigated. The stitching parameters included stitching density, the stitch pitch distance, the stitch line spacing, the sewing yarn materials and the yarn fineness.lt was revealed that the higher the stitching density was, the more the bending property was damaged. The bigger the sewing yarn diameter was, the lower the bending strength was. What's more, when the stitching densities were identical, the stitch line spacing was much more influential than the stitch pitch distance. However, the sewing yarn materials almost had no effect on the bending properties.
The finite element analysis software was used to modal the process of the stretching and bending. The contour plots of stitched composites were compared with those of unstitched ones. By this way, the reason why the tensile and bending properties of stitched composites decreased was explained. At last,considering the deficiencies of this research, we came up with some prospects about the equipment for plain stitching, the non-woven fabric composites and a number of data from various properties of stitched composites.
引文
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[4]K.Sano. Mode I Interlaminar Fracture Toughness and Fracture Mechanism of Angle-ply Carbon/Nylon Laminates. Journal of Composite Materials,1996,30: 650-661.
[5]Y.J.Wang, D.M.Zhao. Characerization of Interlaminar Frature Behaviour of Woven Fabric Reinforced Polymeric Composites. Composites,1995,26:431-449.
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[8]S.Solaimurugan, R.Velmurugan. Influence of In-plane Fibre Orientation on Mode I Interlaminar Fracture Toughness of Stitched Glass/polyester Composites. Composites Science and Technology,2008,68:1742-1752.
[9]金春花.缝纫复合材料的力学性能研究[D].南京航空航天大学,2006：3.
[10]S.L.Huang, R.J.Richey, E.W.Deska. Cross Reinforcement in a GR/EP Laminate. American Society of Mechanical Engineers,Winter Annual Meeting,San Francisco,10-15 December 1978.
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