基于CFRP层合板钻削轴向力时变曲线的钻头几何形状分析

为探索能够实现碳纤维增强复合材料（CFRP）层合板低损制孔的钻头几何形状,采用4种不同几何形状的钻头,对T800级CFRP层合板进行钻孔实验研究,分析了钻头几何形状对钻削轴向力的影响,探讨了钻削轴向力与分层损伤之间的关系。结果表明:轴向力归零速度与出口分层因子有较好的正相关性,可采用钻削轴向力归零速度来表征钻头几何形状对CFRP层合板钻孔的适用性能。同时,实验发现切削区域具有多阶段几何特征的钻头,在钻出工件底部时轴向力是分阶段缓慢归零,出口分层因子较小。      

碳纤维增强树脂基复合材料层合板胶螺混合连接失效机制

为研究碳纤维增强树脂基复合材料(CFRP)层合板单搭接双螺栓胶螺混合连接失效机制,采用基于断裂能断裂准则的连续渐进退化方式,仿真CFRP层合板刚度退化,采用基于能量的B-K准则仿真胶层的损伤演化,建立胶螺混合连接结构渐进损伤三维有限元模型,有限元模型预测的最大失效载荷与实验结果吻合较好。搭接长度L_a为影响胶螺混合接头刚度和强度的重要几何参数,螺栓的位置不会明显影响接头的刚度,粘结面积越大,强度越大。胶螺混合接头在拉伸载荷作用下,由于二次弯曲效应的影响,螺栓向左倾斜,搭接区域的胶层损伤起始于搭接区域胶层外侧,并由外侧向内部扩展到钉孔附近,当胶层损伤扩展到钉孔附近时,螺栓承载增加,胶层和螺栓共同承载,此时CFRP层合板开始出现损伤;最终,左侧钉孔处的上层合板和右侧钉孔处的下层合板产生分层损伤并发生断裂。      

复合材料衬套螺栓干涉连接安装过程损伤机制

复合材料干涉连接结构由于能够显著降低孔周应力集中,提高结构承载能力和疲劳寿命,而成为一种先进的连接形式。但是由于复合材料层间强度低的特点,不合理的干涉螺栓连接结构形式、尺寸以及安装方式很容易引起孔壁分层,降低结构承载能力。针对该问题,本论文提出了一种基于衬套螺栓的干涉连接结构,并对该结构开展了安装过程中承载机制的试验和有限元研究。试验中测量了插钉力变化和孔壁损伤情况,有限元模型中充分考虑了层内损伤和层间分层因素,建立了基于复合材料渐进损伤和内聚力单元的损伤预测模型。通过干涉量为2.2%的衬套螺栓安装过程中的插钉力和损伤的有限元模型与试验结果对比分析发现,二者拟合度良好,证明模型的准确性。通过不同干涉量下的分层情况对比分析以及临界干涉量求解,解释了衬套螺栓提高孔壁质量的原因并提出了可靠干涉量范围。     

复合材料层合板机械连接结构累积损伤模型和挤压性能试验研究

建立了三维累积损伤有限元模型, 采用扩展拉格朗日乘子法对螺栓表面和复合材料层合板孔壁间的接触行为进行了模拟。对复合材料层合板中纤维断裂、基体开裂和纤维2基体剪切3 类基本损伤类型的产生、扩展以及它们之间的关联性进行了研究。计算得到了复合材料层合板单钉连接结构的载荷2位移曲线, 预测了它们的初始挤压破坏载荷。同时, 进行了T300 帘子布/ Q Y8911 双马来酰亚胺树脂层合板单钉单搭螺栓挤压强度试验,验证了不同铺层类型和结构尺寸对复合材料层合板机械连接挤压性能的影响。试验结果和计算结果吻合较好, 证明了该模型和算法的有效性。      

复合材料层合板单钉双剪连接挤压强度的一种工程估算方法

将上限理论应用到复合材料层合板单钉双剪连接挤压强度分析中, 把连接结构的位移场划分为动态区域(层合板)和静态区域(紧固件), 并认为失效发生在位移可动场和不动场之间的钉孔边受挤压部分。由于受挤压孔孔边各层应力状态不一样, 受挤压孔边各层的失效区域和失效模式也各不相同。从宏观上研究复合材料层合板单钉连接孔边的失效区域和失效模式, 结合上限理论提出了一种估算复合材料单钉连接挤压强度的工程算法。通过与试验结果对比, 发现该方法能较好地预测出复合材料单钉双剪连接挤压强度。     

层合板连接结构挤压强度测试方法的研究

利用单钉单剪层合板连接结构挤压性能测试方法和单钉双剪层合板连接结构挤压性能测试方法 (ASTM D 5961A/B),对T700/5429开孔层合板螺栓连接结构的挤压性能进行试验研究,分析不同测试方法对开孔层合板连接结构挤压性能的影响。研究表明:两种试验方法中层合板连接构件均在连接孔处出现有效的挤压破坏形式,但单剪连接试验的稳定性差,影响因素较多,试验数据的离散性较大,且测得的连接结构的极限挤压强度和偏移挤压强度均低于双剪试验的结果。因此,双剪试验方法更适合用于复合材料层合板连接结构设计中挤压许用值的测量。     

复合材料3钉单搭连接有限元模拟与钉载分布

进行了复合材料一铝合金三钉单搭连接单向拉伸试验,测量了层合板面内位移、应变和离面位移随载荷的变化关系,建立了复合材料多钉单搭连接的三维累积损伤有限元模型,计算与试验对比结果表明,该模型可模拟大范围损伤发生之前的承载特性。采用试验和数值模拟相结合的方法研究了复合材料一金属三钉单搭连接钉载分布情况,结果表明：试验用复合材料-铝合金三钉单搭连接,螺栓1承载比例最高,螺栓3次之,中间螺栓的承载比例最低,并且螺栓承载比例在加载过程中基本保持不变;随着金属连接板刚度的增加,螺栓1的承载比例增加,螺栓3承载比例降低,中间螺栓2的承载比例变化较小,层合板离面位移减小;金属板配合间隙变化对钉载分布影响很小,但层合板的离面位移随配合间隙的增大而增大。     

T800碳纤维增强复合材料双剪单钉连接的拉伸试验及强度估算

为系统地研究T800碳纤维增强复合材料螺栓连接的力学性能,首先,对T800碳纤维增强复合材料双剪单钉连接进行了面内准静态拉伸试验,探讨了铺层比例、铺层顺序、螺栓直径以及固化工艺对复合材料螺栓连接刚度和2%偏移挤压强度的影响;然后,根据试验结果得到了T800碳纤维增强复合材料螺栓连接的应力集中减缓因子;最后,结合相应铺层比例的无缺口层合板的应力集中减缓因子和拉伸强度,建立了复合材料连接最终挤压强度的工程算法。结果表明:当螺栓断裂时,连接的最终挤压强度由螺栓剪切强度和螺栓直径/板厚比决定;连接存在挤压和剪切2种失效形式,与±45°铺层比例有关;工程算法的计算结果与试验结果吻合良好。所得试验结果和工程算法可为T800碳纤维增强复合材料螺栓连接的初步设计提供理论依据和技术支持。      

碳纤维增强环氧树脂复合材料层合板结构及间隙尺寸对铆接性能的影响

通过对不同纺织结构的碳纤维增强树脂基复合材料（CFRP）层合板与铝合金（AlMg3）异质材料连接结构进行单剪切拉伸研究,分析间隙尺寸对不同纺织结构CFRP层合板与AlMg3连接结构性能的影响。试验结果表明,当CFRP层合板铺层数目相同时,对于纺织结构不同、间隙配合尺寸相同的CFRP-AlMg3单铆钉单剪切连接结构,编织结构碳纤维增强树脂基复合材料（WO-CFRP）层合板所受挤压应力比非编织结构碳纤维增强复合材料（UD-CFRP）层合板所受挤压应力大25%左右;对于纺织结构相同、间隙配合尺寸不同的CFRP-AlMg3单铆钉单剪切连接结构,其各自铆钉所受剪切应力和连接CFRP层合板所受挤压应力相差不大。同时对相同间隙尺寸、不同纺织结构的CFRP-AlMg3单铆钉单剪切连接结构各个阶段挤压应力分析得知：其他条件一定,各个阶段中WO-CFRP的挤压应力比UD-CFRP的挤压应力高20%左右。最后研究间隙尺寸对CFRP-AlMg3单铆钉单剪切连接结构性能的影响,发现铆钉与孔壁间隙尺寸对位移为铆钉直径大小的4%时的CFRP层合板受到的挤压应力影响较大,铆钉与孔壁间隙大小增加0.1 mm,位移为铆钉直径大小的4%时的CFRP层合板受到的挤压应力降低约17%,而对CFRP层合板的初始损伤应力和破坏应力几乎没有影响,对铆钉所受剪切作用力和AlMg3板材所受挤压应力也几乎没有影响。     

接头局部增强的复合材料层合板螺栓连接试验与数值模拟

采用真空辅助成型工艺（VARI）制备了四种局部增强的复合材料层合板螺栓连接试件，通过试验及数值模拟对其力学性能进行了研究。数值研究中将复合材料层合板连接件的拉伸作为一个准静态问题，运用ABAQUS的显示分析算法及所编写用户材料子程序VUMAT对连接件进行了三维渐进失效模拟，同时在有限元模型中采用内聚力单元模拟了层合板与所设增强层的界面分层失效。数值计算结果与试验结果取得了较好的一致，验证了本文中数值方法的有效性。研究结果表明，不同的局部增强方案对复合材料螺栓连接性能的影响较大，设置[0/90/0/90]_S铺层的内置纤维增强层能显著提高层合板的螺栓连接性能。     

A review of mechanical drilling for composite laminates

Composite laminates (CFRP, GFRP, and fiber metal composite laminates) are attractive for many applications (such as aerospace and aircraft structural components) due to their superior properties. Usually, mechanical drilling operation is an important final machining process for components made of composite laminates. However, composite laminates are regarded as hard-to-machine materials, which results in low drilling efficiency and undesirable drilling-induced delamination. Therefore, it is desirable to improve the cost-effectiveness of currently-available drilling processes and to develop more advanced drilling processes for composite laminates. Such improvement and development will benefit from a comprehensive literature review on drilling of composite laminates. This review paper summarizes an up-to-date progress in mechanical drilling of composite laminates reported in the literature. It covers drilling operations (including conventional drilling, grinding drilling, vibration-assisted twist drilling, and high speed drilling), drill bit geometry and materials, drilling-induced delamination and its suppressing approaches, thrust force, and tool wear. It is intended to help readers to obtain a comprehensive view on mechanical drilling of composite laminates.     

Effect of clamping force on the delamination onset and growth in bolted composite laminates

Clamping force is a key element that alters the mechanism and sequence of failure in bolted joints of composite laminates. The mode of failure in bolted joints can be controlled by geometrical parameters and the preferred fail safe mode of failure is ‘bearing’ which generally consists of matrix cracks, delamination and fibre microbuckling. Three-dimensional (3-D) pinned (without clamping force) and bolted (1 kN clamping force) joint models were developed in [0/90]_s carbon fibre reinforced plastic (CFRP) laminates to show the clamping force effect on the onset and growth of delamination. It is shown that delamination was resulted from the shear stress components (Mode II & III) at the interface and the contribution of the out-of-plane component (Mode I - opening), so the clamping force, was negligible without modelling the in-plane failure modes and their coupling with delamination, which will be considered in future work.     

Instantaneous mechanical fastening of quasi-isotropic CFRP laminates by a self-piercing rivet

A modified self-piercing rivet (SPR) has been proposed to mechanically fasten CFRP laminates. The modified SPR consists of a rivet body and two flat washers. The two flat washers were used to suppress delamination in the CFRP laminates at the point of piercing. The advantages of the modified SPR for fastening CFRP laminates are instantaneous process time and low cost. Any pretreatments such as surface treatments or hole drilling are not required. In this study, the viability of the modified SPR for a quasi-isotropic CFRP laminate was investigated by tensile and fatigue tests on the single lap joints. The experimental results showed that the tensile strength of a modified SPR joint was slightly higher than a bolted joint. In tension–tension fatigue tests, a fatigue limit at N_f = 10⁷ cycles was about 50% of the tensile joint strength. Experimental results showed that the modified SPR was one of the promising fasteners for future mass-production CFRP automobiles.     

Assessment of drilling-induced damage in CFRP under chilled air environment

Drilling holes in carbon fiber-reinforced polymer (CFRP) laminates are more prone to incur damage during machining. Surface damage could be considerably minimized through the adoption of cryogenic assisted machining. The economic and safety implications associated with cryogenic technology necessitate the exploration of alternate technologies. In this research work, the effects of cutting velocity (100, 125, and 150?m/min) and feed rate (0.03, 0.06, and 0.09?mm/rev) on thrust force, surface roughness, delamination, and acoustic emissions are studied during the drilling of CFRP laminates under chilled air environment and compared with dry drilling. The output parameters are found to be much influenced by feed rate than cutting velocity. Under high feed rate and cutting velocity, the delamination factor, surface roughness, and acoustic emissions are, respectively, reduced by 13.2, 10.5, and 7.4% for the drilling performed under chilled air environment over dry condition. About 9.9% increased thrust force is observed for chilled air-assisted drilling under the identical machining condition.     

螺栓夹持填充孔复合材料层压板层间应力分析

为了研究含螺栓复合材料层压板连接接头的层间应力分布规律,提出了采用填充孔形式和虚拟界面层方法求解层间应力,并建立了三维有限元模型对受面内压缩载荷的螺栓夹持填充孔层压板进行分析。结果表明:层压板层间应力集中不仅发生在孔边,还会在螺栓头边缘附近出现,且夹持力越大螺栓头边缘附近的层间应力集中越严重;合理的螺栓夹持力能改善孔边应力状态,提高孔边抵抗分层的能力,但无法改善螺栓头边缘附近的层间剪切应力集中状态。因此,在进行含螺栓夹持的层压板机械连接结构孔边层间强度设计时,也要考虑螺栓头边缘的层间剪切应力集中问题,以提高复合材料结构的安全性。     

An experimental study on fatigue characteristics of CFRP-steel hybrid laminates

This paper aims to investigate the fatigue characteristics of hybrid laminates consisting of wave carbon fiber reinforced polymer (CFRP) sheets and a thin stainless steel plate under the tension–tension loading. Different loading options (e.g. same stress and same force), layers of CFRP sheets, and lay-ups of laminates (single and double sides) were considered. A series of experimental tests were performed to determine the effectiveness of the CFRP bonding on prolonging fatigue crack initiation life, preventing fatigue crack propagation and extending fatigue life of the hybrid laminates. Three distinct failure modes, classified as delamination, delamination bending and fiber breakage, were observed in the tests. It is shown that the loading conditions and CFRP thickness are the critical parameters affecting the failure modes and fatigue resistance. The crack initiation life and fatigue life of fiber-metal laminates (FMLs) increase by factors ranging from 1.06 to 1.96 and 1.17 to 2.07, respectively, relative to monolithic steel plates under the same force condition; whereas decrease by factors ranging from 0.63 to 0.89 and 0.28 to 0.61 under the same stress condition. Moreover, the double-side bonded FMLs show better fatigue properties and more stable crack propagation than single-side counterpart with the same thickness of CFRP.     

考虑刀具磨损影响的CFRP复合材料钻削轴向力预测

在碳纤维增强树脂(CFRP)复合材料钻削过程中,随着刀具磨损量的累积,轴向力会逐渐增加,轴向力过大会导致CFRP复合材料一系列的加工缺陷。为实现在CFRP复合材料钻削过程中随刀具磨损量的累积轴向力变化的有限元分析及预测,建立了CFRP复合材料钻削仿真模型,通过对ABAQUS仿真软件二次开发,利用Python语言开发子程序,将考虑磨损量累积的轴向力预测模型导入仿真软件,运用ABAQUS软件对CFRP复合材料钻削中轴向力进行研究,实现了随着刀具磨损量累积轴向力变化的预测功能。随后通过CFRP复合材料钻削试验,分析了轴向力随钻削孔数的变化规律,以验证轴向力的预测结果。结果表明:3D钻削有限元模型能够良好地预测实际加工过程中刀具未磨损时轴向力的大小,其误差为9.10%;在考虑磨损量累积后,轴向力预测模型能够较准确地预测实际加工过程轴向力的大小,其最大误差不超过10%。      

硬质合金台阶钻结构参数及钻削工艺参数对CFRP开孔性能的影响

基于VMC850B立式加工中心和UltraPAC超声C-扫描仪,搭建了碳纤维增强树脂基复合材料(CFRP)钻削试验平台,探讨了台阶钻结构参数及钻削工艺参数对CFRP钻削过程中的钻削轴向力和分层因子的影响。结果表明,钻削工艺参数对第一段钻削轴向力影响较大,台阶钻结构参数对第二段钻削轴向力的影响较大;分层因子的大小与第一段钻削轴向力和第二段钻削轴向力有关,当第一段和第二段直径比d/D0.5时,分层因子主要与第一段钻削轴向力有关;减小分层的优水平组合为第一段直径2.8mm,第二段锋角95°,主轴转速7000r/min,进给速度2.5mm/s。