连续纤维增强复合材料增材制造预测建模研究进展

doi:10.7527/S1000-6893.2025.32311

Abstract

Abstract:

Continuous Fiber Reinforced Composites （CFRCs） are extensively employed in advanced industries such as aerospace and rail transit， owing to their superior mechanical properties. In recent years， additive manufacturing （3D printing） has emerged as a primary method for fabricating CFRCs， eliminating the limitations of traditional manufacturing processes that rely on molds. This review provides a comprehensive overview of the latest advancements in predictive modeling of CFRCs additive manufacturing， covering the entire technological development pathway from process modeling to structural mechanics modeling of 3D printed CFRCs. The section on process modeling of CFRCs additive manufacturing explores key aspects such as resin flow and infiltration behavior， heat transfer mechanisms， residual stress evolution， and fiber misalignment control. The subsequent section on structural mechanics modeling of 3D printed CFRCs presents mainstream modeling approaches at the micro， meso， and macro scales， highlighting their application scenarios. It also examines the potential of multiscale modeling techniques， which bridge these different scales to enhance predictive accuracy. Finally， this review systematically identifies the major challenges currently faced in predictive modeling of CFRCs additive manufacturing and outlines future research directions. These insights provide theoretical guidance and technical support for advancing the scientific understanding and practical application of high-performance CFRCs in additive manufacturing.

Key words: continuous fiber reinforced composites, additive manufacturing, mechanics modeling, fused filament fabrication, manufacturing processes

CLC Number:

V258

Zhi HAN, Yusi WANG, Wenyao ZHANG, Bing LI, Yuan CHEN. Progress in modeling of additive manufacturing for continuous fiber-reinforced composites[J]. Acta Aeronautica et Astronautica Sinica, 2026, 47(5): 432311.

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Table 1

Table 2

Advantages and disadvantages of 3D printing CFRC structural mechanics modeling methods with specific case studies

建模方法	优势	不足	具体案例数据
微观尺度建模	能够清晰展示纤维与树脂之间的力学特性及界面性能，揭示纤维和树脂的相互作用	难以直接应用于宏观结构的整体性能预测	与圆形纤维单胞模型相比，齿轮形纤维模型在横向拉伸方向上表现出更高的强度。这一增强主要归因于其复杂的截面几何形状，使应力在纤维与基体界面上呈交错分布，有效延缓了界面损伤的萌生与扩展过程，从而提升了整体承载能力^［39］
介观尺度建模	能够获得3D打印纤维增强复合材料的整体结构特征，如内部缺陷和表面形状	界面及局部破坏机理展示不够精细，且难以完全预测宏观力学表现	引入弯曲丝束后，结构的纵向压缩破坏强度显著降低。弯曲丝束试样的破坏主要发生在弯曲丝束与规则丝束接触区域的界面截面，表明该区域为结构的应力集中与失效起始位置^［69］
均质化建模（宏观）	能够快速预测纤维增强效果和宏观力学性能，适用于相对简单的3D打印复合材料结构	无法反映纤维在局部的取向、分布等细节	除结构变形外，该模型还能模拟3D打印复合材料中常见的损伤形式（如层间分层）。此外，仿真预测的吸能和压溃力效率与试验结果的相对误差分别为8.23%和5.08%，表明模型在损伤响应预测方面具有良好的准确性^［80］
路径相关建模（宏观）	能够精确模拟纤维铺放路径对复合材料性能的影响，适用于复杂形状的3D打印复合材料结构	当纤维路径和材料分布较为复杂时，建模和时间成本增加	在压缩载荷作用下，米塞斯应力主要集中于沿纤维路径排布的区域，尤其是在垂直于加载方向的纤维区域中表现得更为显著。这表明纤维路径的几何排列对局部应力分布具有重要影响，最终通过试验结果与路径相关建模和均质化建模发现，最终路径相关建模的刚度、峰值力还有吸收能量的精度相对均质化建模来说分别提高了15.8%，0.4%和2.6%^［33］
多尺度耦合建模	通过从微观到宏观的多尺度结合，可更全面地分析纤维-树脂相互作用和失效机理	参数众多，标定成本高	在微观尺度上，RVE识别纤维增强打印丝束的均匀化弹性性能；在细观尺度上，利用该均匀化特性表征打印丝束行为，并进一步分析孔隙对性能的影响；在宏观尺度上，则基于细观数据确定整体结构的弹性响应。最终所预测的结构强度和弹性模量与试验结果的相对误差分别为3.55%和1.54%，表明所构建的多尺度建模方法具有较高的准确性和可靠性^{［31，48］}

Table 2

Table 3

Advantages and disadvantages of FFF manufacturing process modeling methods with specific case studies

建模方法	优势	不足	具体案例数据
热力耦合建模	能够预测3D打印过程或冷却阶段残余应力导致的翘曲变形，从而通过优化打印参数调控打印过程的温度场	模型复杂度高，且对材料参数依赖较大，材料参数随温度的非线性变化往往难以准确建模	以下为部分常见半结晶聚合物在翘曲试验与仿真对比中的误差范围：聚丙烯（PP）为2.5%~5.8%^［34］，丙烯腈-丁二烯-苯乙烯共聚物（ABS）为12.2%~23.5%^［44］，聚乳酸（PLA）为6%~8%^［28］。这些结果表明，即使在标准材料体系下，试验与仿真之间仍存在一定程度的误差，强调了模型校准的重要性
多物理场耦合建模	综合考虑材料结晶动力学、相变、应力场以及其他物理场的影响，对于半结晶聚合物在FFF等工艺中的形态演化和最终性能具有更强的指导意义	难以获取所有所需的多物理场参数	打印丝束之间的距离增大，相邻打印丝束的粘结面积变小，碳纤维未被树脂浸润的面积增大，模型Ⅱ的未浸润面积和纤维体积分数分别降低了2.68%和0.8%^［48］
流变及浸润过程建模	研究树脂在连续纤维增强复合材料中的流动和浸润特性，能更好地揭示打印过程中材料融合、浸润和界面结合的机理	当纤维排布复杂时，计算或模型简化的难度较高	预测的浸渍率随各工艺参数增加的趋势与试验结果一致，除了在最低打印速度（4 mm·s^-1）下得到的结果外，试验结果与预测值的相对误差平均值均小于10%^{［29，51］}
流固耦合建模	适用于模拟树脂流动以及纤维与树脂间的相互作用	仅适用于局部区域的小尺度分析	短纤维增强ABS在流动中呈现取向差异：流道中部纤维保持流动方向；接触打印床后纤维取向偏离；对于连续纤维增强尼龙：树脂挤出时形成双向分裂流，纤维被推向喷嘴内壁。打印头移动导致树脂速度左快右慢^［30］

Table 3

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CFRC预测建模	建模方法	计算方法	网格类型	连续纤维类型	树脂类型	文献
3D打印CFRC 结构力学建模	微观尺度建模	FEM（RVE）	实体	Carbon、Glass	PA	［32，62，64］
	介观尺度建模	FEM	实体	Carbon	PA	［69-70］
	一体化建模（宏观）	FEM	实体、壳单元	Carbon	PA、PLA	［80，82，84］
	路径相关建模（宏观）	FEM	实体	Carbon、Kevlar	PA、PLA	［9，57，79］
	多尺度建模	FEM	实体	Carbon	PA	［29，31，71］
FFF制造成型过程建模	热-力耦合建模	FEM（生死单元法）	实体	Carbon	PLA	［47］
	多物理场耦合建模	FEM	实体	Carbon	ABS	［48，71］
	流变及浸润过程建模	FEM	实体	Carbon	PLA	［29，51］
	流固耦合建模	SPH、DEM	无网格	Carbon、Short Glass	PA、ABS	［30］

Progress in modeling of additive manufacturing for continuous fiber-reinforced composites

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