复合材料机翼结构热校形工艺实验及数值模拟

纤维增强树脂基复合材料机翼结构复杂,往往存在明显的固化变形现象,严重影响机翼的装配和气动特性。本研究目的在于建立大型复合材料复杂结构的热校形工艺方法,解决复合材料机翼制造的变形控制问题。针对复合材料机翼的固化变形特点,设计了新的热校形夹具工装。在评价复合材料应力松弛特性的基础上,建立了大型复合材料机翼结构热校形工艺的有限元模拟方法,实现了对热校形后机翼结构残余变形的有效预报,分析了校形载荷、校形温度等关键工艺参数对校形效果的影响规律,形成优化的热校形工艺方案。模拟及实验结果表明,复合材料热校形工艺可以适用于大型复杂结构,复合材料机翼89.5%的固化变形被热校形工艺的残余变形抵消,达到机翼的装配和气动外形要求。      

织物增强复合材料梁结构热校形工艺

本文借鉴金属零件热校形工艺的经验,利用复合材料在高温下的应力松弛现象,通过热校形工艺修正复合材料零件的形状。制造了碳纤维平纹织物/环氧复合材料L形梁、C形梁,通过自制的热校形模具,以实验方法研究热校形时间、热校形载荷对零件形状的影响,分析复合材料热校形工艺的可行性。研究表明,复合材料热校形工艺中零件变形的主要原因是零件在高温下发生应力松弛,其他因素可以忽略;热校形载荷、热校形时间都对热校形工艺的效果有重要影响。针对特定的复合材料结构,采用合理的热校形工艺过程能够有效地控制构件形状,方便零件的装配。     

Repair of shear-deficient normal weight concrete beams damaged by thermal shock using advanced composite materials

The use of advanced composite materials such as Fiber Reinforced Polymers (FRPs) in repairing and strengthening reinforced concrete structural elements has been increased in the last two decades. Repairing and strengthening damage structures is a relatively new technique. The aims of this study was to investigate the efficiency and effectiveness of using Carbon Fiber Reinforced Polymer (CFRP) to regain shear capacity of shear-deficient normal weight high strength RC beams after being damaged by thermal shock. Sixteen high strength normal weight RC beams (100 × 150 × 1400 mm) were cast, heated at 500 °C for 2 h and then cooled rapidly by immersion in water, repaired, and then tested under four-point loading until failure. The composite materials used are carbon fiber reinforced polymer plates and sheets. The experimental results indicated that upon heating then cooling rapidly, the reinforced concrete (RC) beams exhibited extensive map cracking without spalling. Load carrying capacity and stiffness of RC beams decreased about 68% and 64%, respectively, as compared with reference beams. Repairing the thermal damaged RC beams allowed recovering the original load carrying without achieving the original stiffness. Repaired beams with CFRP plates with 90° and 45° regained from 90% to 99% of the original load capacity with a corresponding stiffness from 79% to 95%, whereas those repaired with CFRP sheet on the web sides and a combination of CFRP plates and sheet regained from 102% to 107% of the original load capacity with a corresponding stiffness from 81% to 93%, respectively. Finally, finite element analysis model is developed and validated with the experimental results. The finite element analysis showed good agreement as compared with the experimental results in terms of load–deflection and load–CFRP strain curves.     

Design and manufacturing of an L-shaped thermoplastic composite beam by braid-trusion

Braid-trusion is a manufacturing process for composite materials in which a braiding machine is coupled with a pultrusion die to continuously produce beams with constant cross-section and off-axis fiber orientation. This study presents a geometrical model of the tri-axial braid which allows the design of braided preforms that achieve correct filling of the pultrusion die at the same time as it limits fiber friction on die walls. The typic design parameters are listed and used for the manufacturing of a braid-truded thermoplastic composite beam where fibers are aligned at ±69° as well as 0° with respect to the beam axis. Tensile mechanical characterization and cross-section observations are also presented.     

High strain rate superplasticity of hot extruded and hot rolled AA 6013/20 vol.-%SiCp composite

Abstract

High strain rate superplasticity(HSRS)of an AA 6013/20SiC_pcomposite, produced by powder metallurgy and then hot extruded or hotrolled, was evaluated by means of tensile tests carried out over a range of initial strain rates from 1 × 102 to 3.8 × 10^-1 s^-1 and temperatures from 520 to 590 ° C. A maximum elongation to failure of 370% was achieved in a hot rolled composite deformed at 1 × 10^-1 s^-1 and 560 ° C. Substantially lower elongations were achieved in hot extruded composites, with a maximumof200% at1 × 10^-2 s ^-1 and 580 ° C. The lower elongations in the hot extruded composite could be related to the large quantity of intermetallic compounds, shown by TEM analyses, which probably hinder large superplastic elongations. In both hot extruded and hot rolled composite, the flow stress was strongly dependenton temperature and strain rate; a steady state flow stress region was observed in the specimen that exhibited the maximum elongation to failure. The strain rate sensitivity index m reached a maximum ofabout 0.4 for the hot rolled composite, and about 0.35 for the hot extruded composite. Analyses of the fracture surfaces of hot rolled composite deformed at the maximum elongation, were characterised by the presence of many filaments or 'whiskers', which are generally considered as evidence of a liquid phase present at grain boundaries or interfaces.     

小曲率铝合金框形件弯胀成形数值模拟研究

目的 针对一种小曲率铝合金框形件成形后回弹大和起皱问题,对其进行弯胀复合成形工艺的数值模拟研究。方法 基于DYNAFORM软件对成形过程进行仿真,并通过对比分析零件的最大减薄率及圆角处的贴膜度,得出该零件最大液室压力的最优值为20 MPa,并基于该参数进行壁厚分布及回弹的模拟分析,最后,通过现场试验对该成形方案进行验证。结果 通过采用弯胀复合成形工艺方法,该零件的最大回弹量控制在2 mm以内,零件整体成形质量较好,无破裂、起皱现象。结论 该种成形方法较刚性模压弯及主动式充液胀形更具优势,能够有效解决小曲率框形件回弹大及起皱问题。     

基于模具-制件相互作用的复合材料制件固化变形数值模型

针对复合材料制件在成型过程中的固化变形这一关键技术问题,通过在模具与复合材料制件之间引入剪切层的方法,建立了预测复合材料制件固化变形的解析计算模型和有限元仿真模型。剪切层的剪切模量用来衡量固化过程中模具与复合材料制件之间的相互作用,其数值大小通过与实验数据进行比对而得到。基于建立的固化变形模型,与文献中已有的实验结果进行了比较。结果表明:所建立的模型具有较高的可靠性。同时针对L型复合材料制件建立了三维有限元仿真模型,模型中除考虑材料各向异性和化学收缩效应以外,还将成型过程中模具与复合材料制件间的相互作用考虑在内。模拟结果表明:引入模具作用后L型零件的固化变形预测结果更加准确。      

Multi-regression modeling for springback effect on automotive body in white stamped parts

The use of high strength steel (HSS) materials in automotive body in white (BIW) stamped parts has increased the occurrence of springback after the forming process. Although HSS exhibits superior strength, weight reduction, and crash energy, it strongly influences springback impact on the sustainable development of BIW stamped parts. In this study, an empirical springback prediction model was synthesized based on the contemporary data sets of springback-prone components of automotive BIW stamped parts. Two different BIW stamped parts from an actual industrial stamping production line were selected as pilot parts for this study. A statistical multi-regression (MR) analysis was used to model the springback prediction effect by examining the sensitivity of springback input parameters on existing die geometry. The outputs represent the total springback values of the stamped parts. A total of 240 data from samples of selected stamped parts were tabulated to synthesize the springback prediction model. The results show that the MR models for the two parts were linear with the springback estimated errors between the measured and predicted values between 0.5° and 3°, which is acceptable from an industrial viewpoint. The proposed MR models are capable of predicting the springback effect with minimal error by incorporating all possible variations that are inherent in the shop floor process.     

定型剂对经编织物液态成型复合材料工艺性及其力学性能的影响

研究了双马来酰亚胺树脂定型剂含量对0°/90°双轴向经编织物(Non-crimp fabric,NCF)定型效果、液态成型工艺性、复合材料力学性能的影响。采用厚度回弹、C型回弹的方法表征定型效果;采用厚度压缩与偏轴拉伸实验表征带定型剂织物成型工艺性;并采用弯曲实验与层间剪切实验表征复合材料力学性能。实验结果表明定型剂的添加显著提高了NCF织物的预定型效果;经定型剂处理后NCF织物的面内剪切模量有了较大提高,抗剪切变形能力增强;添加定型剂对0°/90°双轴向NCF织物复合材料的力学性能影响不大,但在改善其工艺性的同时并不会降低其复合材料的力学性能。     

Fatigue behavior of RC T-beams strengthened in shear with EB CFRP L-shaped laminates

The use of externally bonded carbon fiber-reinforced polymer (EB-CFRP) to strengthen deficient reinforced concrete (RC) beams has gained in popularity and has become a viable and cost-effective method. Fatigue behavior of RC beams strengthened with FRP is a complex issue due to the multiple variables that affect it (applied load range, frequency, number of cycles). Very few research studies have been conducted in shear under cyclic loading. The use of prefabricated CFRP L-shaped laminates (plates) for strengthening RC beams under static loading has proven to be technically feasible and very efficient. This study aimed to examine the fatigue performance of RC T-beams strengthened in shear for increased service load using prefabricated CFRP L-shaped laminates. The investigation involved six laboratory tests performed on full-size 4520 mm-long T-beams. The specimens were subjected to fatigue loading up to six million load cycles at a rate of 3 Hz. Two categories of specimens (unstrengthened and strengthened) and three different transverse-steel reinforcement ratios (Series S0, S1, and S3) were considered. Test results were compared with the upper fatigue limits specified by codes and standards. The specimens that did not fail in fatigue were then subjected to static loading up to failure. The test results confirmed the feasibility of using CFRP L-shaped laminates to extend the service life of RC T-beams subjected to fatigue loading. The overall response was characterized by an accelerated rate of damage accumulation during the early cycles, followed by a stable phase in which the rate slowed significantly. In addition, the strains in the stirrups decreased after the specimens were strengthened with CFRP, despite the higher applied fatigue loading. Moreover, the addition of L-shaped laminates enhanced the shear capacity of the specimens and changed the failure mode from brittle to ductile under static loading. Finally, the presence of transverse steel in strengthened beams resulted in a substantially reduced gain in shear resistance due to CFRP, confirming the existence of an interaction between the transverse steel and the CFRP.     

Delamination properties of z-pinned composites in hot–wet environment

The effect of hot–wet environment (75 °C and 85% relative humidity) on the delamination fracture properties and interlaminar toughening mechanisms of z-pinned carbon fibre–epoxy composite is investigated. The absorption rate of water from the hot–wet environment into the composite is accelerated slightly by z-pins, although the pins did not change the saturation limit of the material. Absorbed water weakens the pin/composite interface and this lowers the ultimate elastic traction load generated by z-pins under mode I interlaminar loading. However, once the pin/composite interface has failed, the traction load and energy required to pull-out the z-pins is not affected by absorbed water. The mode I interlaminar fracture toughness and low-energy impact damage resistance of z-pinned composites is not degraded significantly by exposure to hot–wet environment, and this is because absorbed water does not affect the pull-out traction properties of z-pins.     

基于补偿因子的直弯边下陷零件回弹补偿研究

橡皮成形是飞机钣金零件制造的一种重要成形工艺,回弹是橡皮成形过程中主要缺陷之一.为提高钣金零件橡皮成形效率,基于补偿因子对下陷区回弹补偿进行研究,实现钣金零件一步法成形.首先对弯曲回弹公式进行推导,结合弯曲过程中刚度概念引出补偿因子作为直弯边下陷零件回弹补偿公式;然后利用CATIA二次开发功能将补偿公式写入程序并与数据库进行连接,并对直弯边下陷零件进行回弹补偿;采用Pamstamp 2G软件对橡皮成形过程进行有限元模拟,通过实际成形试验对带补偿因子的回弹公式进行验证,最后将模拟值和试验值进行比较.结果表明:有限元模拟过程能够很好的预测回弹,补偿结果达到精准成形要求且误差在0.5°范围内,成形压力对回弹影响很小.对于下陷成形,需要较大的成形压力才能达到一次成形的目的,验证了补偿因子回弹公式的可靠性.     

纵梁前段全工序回弹预测与控制

目的结合高强度钢板纵梁前段工艺难点及特征,提出对该零件回弹进行预测和控制的方法。方法采用经验设计和CAE分析技术相结合的方法,对零件全工序成形及回弹过程进行了仿真模拟分析,同时对零件产生回弹的原因进行了深入分析,提出了回弹问题的解决方案。结果通过采取有效措施对回弹进行控制,成功解决了零件质量问题,回弹控制在了1 mm之内,平均合格率达到了91.8%,满足了装车要求。结论全工序CAE分析可有效预测高强度钢板梁类零件的成形质量缺陷和回弹状态,并指导工艺设计和模具型面补偿,合理的梁类扭曲回弹解决方案为类似零件模具的开发提供了参考。     

Improved mechanical properties of an epoxy glass–fiber composite reinforced with surface organomodified nanoclays

An organomodified surface nanoclay reinforced epoxy glass-fiber composite is evaluated for properties of mechanical strength, stiffness, ductility and fatigue life, and compared with the pristine or epoxy glass-fiber composite material not reinforced with nanoclays. The results from monotonic tensile tests of the nanoclay reinforced composite material at 60 °C in air showed an average 11.7% improvement in the ultimate tensile strength, 10.6% improvement in tensile modulus, and 10.5% improvement in tensile ductility vs. these mechanical properties obtained for the pristine material. From tension–tension fatigue tests at a stress-ratio = +0.9 and at 60 °C in air, the nanoclay reinforced composite had a 7.9% greater fatigue strength and a fatigue life over a decade longer or 1000% greater than the pristine composite when extrapolated to 10⁹ cycles or a simulated 10-year cyclic life. Electron microscopy and Raman spectroscopy of the fracture and failure modes of the test specimens were used to support the results and conclusions. This nanocomposite could be used as a new and improved material for repair or rehabilitation of external surface wall corrosion or physical damage on piping and vessels found in petrochemical process plants and facilities to extend their operational life.     

复合材料Ⅴ型构件的固化变形预测及其工装型面设计

利用固化动力学模型对20 mm厚度和3mm厚度的ZT7H/5429碳纤维复合材料层合板进行了固化模拟,在固化过程中,20 mm厚度平板出现了温度峰值,中心温度与表面温度差不超过6℃,3mm平板温度分布均匀,温度历程与热压罐工艺温度基本一致.利用简化的温度场和等效热膨胀系数对609和90°拐角的Ⅴ型基准试件进行了固化变形模拟,并进行了Ⅴ型基准试件的固化试验.60°和90°拐角试件的固化回弹角的模拟值分别为1.58°和1.18°,试验测得的回弹角的平均值分别为1.59°和1.11°.对Ⅴ型复合材料蒙皮构件进行了固化变形模拟,并得到了补偿过的工装型面,在该工装上成型的试件与设计形状基本一致.     

Occurrence and numerical prediction of surface defects during flanging of metallic sheets

Surface defects can develop on automotive exterior panels after drawing and flanging steps, during springback and may alter significantly the vehicle quality. These defects are characterized by a small depth below 0.5 mm and are then difficult to detect numerically. This study focuses on the surface defects for two parts: an industrial upper corner of a front door and a L-shaped part designed on purpose to reproduce at a small scale surface defects that occur after flanging. Dimensions of these defects are measured from profiles obtained either with a non-contacting method or a tridimensional measuring machine. Numerical simulations of the processes are performed with the commercial codes PamStamp2G or Abaqus and deformed meshes are analyzed in the same way as the experimental data. There is a good correlation between experiments and simulations concerning the spatial position of the defect and their dimensions. Moreover, a buckling analysis during springback is performed for the L-shaped part, showing that the position of the defect corresponds to one of the buckling mode.     

基于 AHP 与灰色系统理论的隔热件成形回弹控制优化

目的汽车隔热件的冲压成形过程比较复杂,成形工艺参数较多,实际生产难以准确地建立起工艺参数与质量目标之间的联系,研究工艺参数对成形质量及回弹的影响为实际生产提供指导必要而有意义。方法对模具间隙、凹模圆角半径、摩擦因数等影响回弹的因素进行正交试验,设计了试验方案,获得了成形零件的回弹数据;结合层次分析理论(APH)计算了成形工艺参数对多质量目标的权重,最后利用灰色系统理论,计算出了成形质量相对目标函数的关联度,再进行进一步计算获得各成形工艺参数的平均关联度,将优化后的工艺参数应用于有限元仿真与实验验证。结果通过层次分析理论和灰色系统理论对成形工艺参数进行优化,获得了优化工艺参数组合,隔热件成形质量明显提高,回弹量控制在较小范围内。结论当模具间隙为0.805 mm、凹模圆角半径为12 mm、摩擦因数为0.125时,回弹前后距离差Δd=0.918 mm、回弹前后夹角差Δα=0.340°,回弹得到有效控制。     

汽车侧围前连接板冲压成形质量优化研究

针对汽车侧围前连接板的成形质量缺陷问题,本文通过有限元软件分析工艺参数对成形质量的影响,并完成拉延模面的回弹补偿。首先,以最大减薄率和最大回弹量为评价目标,采用正交实验对压边力、模具间隙、冲压速度和摩擦系数4个工艺参数进行分析,获得影响成形质量最大的因素为压边力,冲压速度次之,确定最优工艺参数为:压边力300 kN、模具间隙1.20 mm、冲压速度90 mm/s、摩擦系数0.11;其次,采用节点位移法对拉延模面进行2次回弹补偿,将零件的回弹量控制在允许范围内;最后,将最优工艺参数和回弹补偿面应用于现场实验,测得试模件的最大减薄率为14.64%,最大正负回弹量为1.254 4 mm/-1.327 0 mm,试模件的最大减薄率和最大回弹量均在允许范围内,实验结果与仿真分析结果相近,验证了本实验方案的可行性。研究表明:通过优化工艺参数能够有效控制减薄、起皱和拉延不足等缺陷,并能够在一定程度上减少回弹量;通过对拉延模进行回弹补偿可以有效地控制回弹量。     

Repair of heat-damaged RC shallow beams using advanced composites

Several repair techniques for restoring the structural capacity of heat-damaged high-strength reinforced concrete shallow beams using advanced composites are proposed. A series of 16 under-reinforced concrete hidden beams were cast, heated at 600°C for 3 h, repaired, and then tested under four point-loading. Tests were conducted to study the effectiveness of externally applied composite materials on increasing the flexural capacity of beams. The composites used include high strength fiber reinforced concrete jackets; ferrocement laminates; and high-strength fiber glass sheets. The beams repaired with steel and high performance polypropylene fiber reinforced concrete jackets regained up to 108 and 99% of the control beams’ ultimate load capacity, with a corresponding increase in stiffness of up to 104 and 98%, respectively. The beams repaired with fiber glass sheets and ferrocement meshes regained up to 126 and 99% of the control beams’ ultimate load capacity, with a corresponding increase in stiffness of up to 160 and 156%, respectively. Most of the beams repaired showed a typical flexural failure with very fine and well-distributed hairline cracks in the constant moment region.     

Aging of a polymer core composite conductor: Mechanical properties and residual stresses

Polymer core composite conductor specimens were aged in atmospheric conditions at 140 and 180 °C and then tested under four point bending. When aged up to a year at a temperature of 140 °C no detrimental effect on flexural performance of the composite was observed, as opposed to aging at 180 °C, which had a very negative effect on the properties. A finite element model was developed to characterize the residual stress in the composite on a micro scale using representative volume elements (RVE). The residual stresses developed after aging at 140 °C for a year were minimal. However, at temperatures higher than 160 °C significant increases in the stresses were observed. The effect of chemical aging on the failure process of the rods was not considered but could result in the rapid reduction in the loads at failure for the rods tested at 180 °C for up to a year.