近零应力等效温度场驱动的CFRP复杂构件固化变形控制方法
收稿日期: 2023-10-11
修回日期: 2023-11-28
录用日期: 2023-12-08
网络出版日期: 2023-12-21
基金资助
国家自然科学基金面上项目(52175466)
Optimized distortion control method of CFRP curing region temperature field driven by near⁃zero stress equivalent temperature field
Received date: 2023-10-11
Revised date: 2023-11-28
Accepted date: 2023-12-08
Online published: 2023-12-21
Supported by
National Natural Science Foundation of China(52175466)
碳纤维树脂基复合材料(CFRP)构件的固化变形直接影响构件装配后的力学性能及服役寿命。现阶段采用的修模、结构优化等固化变形控制方法存在工艺周期长,迭代成本高等问题。微波加热和自阻电热等选择性加热方法有潜力实现固化温度场的精准调控,进而通过构造不均匀温度场产生热应力来对冲原有的固化变形。针对如何构造不均匀温度场这一典型反问题,推导并定义出近“零应力”等效温度场,原理上可对冲构件脱模前的残余应力场实现近“零应力”固化,从而抑制脱模后的固化变形。针对实际固化温度工艺约束,设计了自适应压缩分割算法对理论等效温度场进行近似分区。在典型双曲面零件和回转体零件上进行了初步验证,相比于传统的等温固化工艺,固化变形和残余应力均减少了近50%;相比于仅考虑固化变形的温度工艺优化方法,固化变形和残余应力均减少了近15%。
关键词: 碳纤维树脂基复合材料; 固化变形; 分区温度场; 图像处理; 变形控制
曹关关 , 许可 . 近零应力等效温度场驱动的CFRP复杂构件固化变形控制方法[J]. 航空学报, 2024 , 45(16) : 429703 -429703 . DOI: 10.7527/S1000-6893.2023.29703
The cure-induced distortion of Carbon Fiber Resin Matrix Composite (CFRP) components directly affects the mechanical properties and service life of the components after assembly. However, the cure-induced distortion control methods such as tool compensation and structure optimization have the problems of long process cycle time and high cost of iteration. Selective heating methods, such as microwave heating and self-resistive heating, have the potential to realize precise control of the curing temperature field, and generate thermal stresses to hedge the original cure-induced distortion by constructing an uneven temperature field. In this paper, the typical inverse problem of how to construct an inhomogeneous temperature field, a quasi “zero-stress” equivalent temperature field is derived and defined, which in principle can hedge the residual stress field of the component before demolding to achieve a quasi “zero-stress” curing, and thus inhibit the curing deformation after demolding. An adaptive compression partitioning algorithm is designed to partition the theoretical equivalent temperature field with respect to the actual curing temperature process constraints. The method is preliminarily validated on typical hyperbolic and rotary parts, and the results show that compared with isothermal curing, the curing deformation and residual stress are reduced by nearly 50%; compared with the temperature field optimization method that only considers the curing deformation, the curing deformation and residual stress are also reduced by nearly 15%.
1 | ZHANG C, ZHANG G L, XU J, et al. Review of curing deformation control methods for carbon fiber reinforced resin composites[J]. Polymer Composites, 2022, 43(6): 3350-3370. |
2 | WANG B, FAN S J, CHEN J P, et al. A review on prediction and control of curing process-induced deformation of continuous fiber-reinforced thermosetting composite structures[J]. Composites Part A: Applied Science and Manufacturing, 2023, 165: 107321. |
3 | PENG X B, XU J, CHENG Y, et al. The effect of curing deformation on the vibration behavior of laminated composite beams[J]. Composite Structures, 2021, 277: 114642. |
4 | JOOSTEN M W, AGIUS S, HILDITCH T, et al. Effect of residual stress on the matrix fatigue cracking of rapidly cured epoxy/anhydride composites[J]. Composites Part A: Applied Science and Manufacturing, 2017, 101: 521-528. |
5 | WANG H. Effect of spring-in deviation on fatigue life of composite elevator assembly[J]. Applied Composite Materials, 2018, 25(6): 1357-1367. |
6 | KAPPEL E. Compensating process-induced distortions of composite structures: A short communication[J]. Composite Structures, 2018, 192: 67-71. |
7 | GALI?SKA A. Compensation of process-induced deformations of double-curved carbon-epoxy composite elements[J]. Polymer Composites, 2019, 40(9): 3666-3677. |
8 | LIU Z D, ZHENG X T, FAN W J, et al. An alternative method to reduce process-induced deformation of CFRP by introducing prestresses[J]. Chinese Journal of Aeronautics, 2022, 35(8): 314-323. |
9 | WHITE S R, HAHN H T. Cure cycle optimization for the reduction of processing-induced residual stresses in composite materials[J]. Journal of Composite Materials, 1993, 27(14): 1352-1378. |
10 | JUNG W K, CHU W S, AHN S H, et al. Measurement and compensation of spring-back of a hybrid composite beam[J]. Journal of Composite Materials, 2007, 41(7): 851-864. |
11 | ZHANG W C, XU Y J, HUI X Y, et al. A multi-dwell temperature profile design for the cure of thick CFRP composite laminates[J]. The International Journal of Advanced Manufacturing Technology, 2021, 117(3): 1133-1146. |
12 | KRAVCHENKO O G, KRAVCHENKO S G, PIPES R B. Cure history dependence of residual deformation in a thermosetting laminate[J]. Composites Part A: Applied Science and Manufacturing, 2017, 99: 186-197. |
13 | KIM H S, YOO S H, CHANG S H. In situ monitoring of the strain evolution and curing reaction of composite laminates to reduce the thermal residual stress using FBG sensor and dielectrometry[J]. Composites Part B: Engineering, 2013, 44(1): 446-452. |
14 | NAWAB Y, BOYARD N, JAQUEMIN F. Effect of pressure and reinforcement type on the volume chemical shrinkage in thermoset resin and composite[J]. Journal of Composite Materials, 2014, 48(26): 3191-3199. |
15 | HUI X Y, XU Y J, ZHANG W C, et al. Multiscale collaborative optimization for the thermochemical and thermomechanical cure process during composite manufacture[J]. Composites Science and Technology, 2022, 224: 109455. |
16 | NAWAB Y, TARDIF X, BOYARD N, et al. Determination and modelling of the cure shrinkage of epoxy vinylester resin and associated composites by considering thermal gradients[J]. Composites Science and Technology, 2012, 73: 81-87. |
17 | BELLINI C, SORRENTINO L, POLINI W, et al. Spring-in analysis of CFRP thin laminates: Numerical and experimental results[J]. Composite Structures, 2017, 173: 17-24. |
18 | STEFANIAK D, KAPPEL E, SPR?WITZ T, et al. Experimental identification of process parameters inducing warpage of autoclave-processed CFRP parts[J]. Composites Part A: Applied Science and Manufacturing, 2012, 43(7): 1081-1091. |
19 | QIAO W, YAO W X. Modelling of process-induced deformation for composite parts considering tool-part interaction[J]. Materials, 2020, 13(20): E4503. |
20 | XUE J, WANG W X, TAKAO Y, et al. Reduction of thermal residual stress in carbon fiber aluminum laminates using a thermal expansion clamp[J]. Composites Part A: Applied Science and Manufacturing, 2011, 42(8): 986-992. |
21 | GAO H J, ZHANG Y D, WU Q, et al. Fatigue life of 7075-T651 aluminium alloy treated with vibratory stress relief[J]. International Journal of Fatigue, 2018, 108: 62-67. |
22 | MARTíN V, VáZQUEZ J, NAVARRO C, et al. Effect of shot peening residual stresses and surface roughness on fretting fatigue strength of Al7075-T651[J]. Tribology International, 2020, 142: 106004. |
23 | WANG X Q, CHOU K. The effects of stress relieving heat treatment on the microstructure and residual stress of Inconel 718 fabricated by laser metal powder bed fusion additive manufacturing process[J]. Journal of Manufacturing Processes, 2019, 48: 154-163. |
24 | LIU K, YE J R, ZHANG B M, et al. Experimental and finite element studies on hot sizing process for L-shaped composite beams[J]. Composites Part A: Applied Science and Manufacturing, 2016, 87: 161-169. |
25 | MATSUZAKI R, YOKOYAMA R, KOBARA T, et al. Multi-objective curing optimization of carbon fiber composite materials using data assimilation and localized heating[J]. Composites Part A: Applied Science and Manufacturing, 2019, 119: 61-72. |
26 | LIU S T, LI Y G, GAN J Y, et al. Active control of cure-induced distortion for composite parts using multi-zoned self-resistance electric heating method[J]. Journal of Manufacturing Processes, 2023, 93: 47-59. |
27 | XU K, LI Y G, CAO G G, et al. Thermally controlled shape programming via image-based optimization towards distortion-reduced composite curing[J]. Journal of Manufacturing Systems, 2023, 70: 230-243. |
28 | 丁安心, 李书欣, 倪爱清, 等. 热固性树脂基复合材料固化变形和残余应力数值模拟研究综述[J]. 复合材料学报, 2017, 34(3): 471-485. |
DING A X, LI S X, NI A Q, et al. A review of numerical simulation of cure-induced distortions and residual stresses in thermoset composites[J]. Acta Materiae Compositae Sinica, 2017, 34(3): 471-485 (in Chinese). | |
29 | LUO L, ZHANG B M, ZHANG G W, et al. Rapid prediction of cured shape types of composite laminates using a FEM-ANN method[J]. Composite Structures, 2020, 238: 111980. |
/
〈 |
|
〉 |