Effect of process-induced residual stress on strength of UAV composite wing

LIU Zhendong; ZHENG Xitao; FAN Wenjing; ZHANG Dongjian

doi:10.7527/S1000-6893.2022.26117

ACTA AERONAUTICAET ASTRONAUTICA SINICA >

2022 , Vol. 43 >Issue 6: 526117 - 526117

DOI: https://doi.org/10.7527/S1000-6893.2022.26117

Articles

Effect of process-induced residual stress on strength of UAV composite wing

LIU Zhendong ,
ZHENG Xitao ,
FAN Wenjing ,
ZHANG Dongjian

Expand

School of Aeronautics, Northwestern Polytechnical University, Xi'an 710072, China

Received date: 2021-07-16

Revised date: 2022-06-22

Online published: 2022-02-28

Supported by

Natural Science Basic Research Program of Shaanxi (2020 JQ-113)

Fold

Abstract

The fabrication process has considerable effect on the performance of fully-cured composite structures. During the curing process, the process-induced residual stress and deformation are generated due to the chemical shrinkage and mismatch of thermal expansion coefficient, et al. The residual stress can potentially lower the performance of composite structures, or even leads to such defects like delamination. Therefore, it is necessary to study the influence of residual stress on the strength of composite structures. Firstly, based on anisotropic viscoelastic constitutive model, a numerical model predicting the residual stress and cure deformation of composite specimen was established. The 3D viscoelastic model was employed in this model and its corresponding finite element code was incurporated into ABAQUS, the relative error of cure deformation between numerical results and experimental data was less than 8.24%. Secondly, a strength predicting numerical model based on the Hashin damage criteria was built. The numerical results have been proved to fit the experimental data in good agreement, the relative error in strength is 9.85%. Then, the residual stress was conducted into the strength predicting model as an initial condition. Thus, the effect of residual stress on the strength of Unmanned Aerial Vehicle (UAV) composite wing structures was numerically studied. To study the effect of different residual stress level on the strength behavior of UAV composite wing structure, 2 different curing parameters were generated. The numerical results show that the residual stress is harmful for the strength behavior of this UAV composite wing structure. The numerical ultimate strength of wing structure was reduced by 3.52% due to the curing residual stress. However, the strength of the wing structure with optimized curing parameter is 1.3% higher than that of the original one.

Key words： process-induced residual stress; process-induced deformation; curing parameter; composite wing; structural strength

Cite this article

LIU Zhendong , ZHENG Xitao , FAN Wenjing , ZHANG Dongjian . Effect of process-induced residual stress on strength of UAV composite wing[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022 , 43(6) : 526117 -526117 . DOI: 10.7527/S1000-6893.2022.26117

References

[1] 王雪明, 谢富原. 碳纤维/双马树脂复合材料整体成型过程分层扩展行为实验研究[J]. 航空学报, 2021, 42(2):424918. WANG X M, XIE F Y. Experimental study on behavior of delamination propagation of carbon fiber/bismaleimide composites during integral forming process[J]. Acta Aeronautica et Astronautica Sinica, 2021, 42(2):424918(in Chinese).
[2] XU X H, WANG X Q, WEI R, et al. Effect of microwave curing process on the flexural strength and interlaminar shear strength of carbon fiber/bismaleimide composites[J]. Composites Science and Technology, 2016, 123:10-16.
[3] LIAN J Y, XU Z B, RUAN X D. Analysis and control of cured deformation of fiber-reinforced thermosetting composites:A review[J]. Journal of Zhejiang University-SCIENCE A, 2019, 20(5):311-333.
[4] 郑锡涛, 刘振东, 梁晶. 大型复合材料构件固化变形分析方法研究进展[J]. 航空制造技术, 2015, 58(14):32-35. ZHENG X T, LIU Z D, LIANG J. Research progress of curing deformation analysis method for large composite structures[J]. Aeronautical Manufacturing Technology, 2015, 58(14):32-35(in Chinese).
[5] 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).
[6] LIU Z D, ZHENG X T, GAO L, et al. Comparative study on the effect of cure parameters on residual deformation for thermoset composite laminates[J]. Journal of Composite Materials, 2021, 55(19):2591-2604.
[7] WANG Q, YANG X F, ZHAO H X, et al. Microscopic residual stresses analysis and multi-objective optimization for 3D woven composites[J]. Composites Part A:Applied Science and Manufacturing, 2021, 144:106310.
[8] ZHANG D, ZHENG X T, WU T C. Damage characteristics of open-hole laminated composites subjected to longitudinal loads[J]. Composite Structures, 2019, 230:111474.
[9] 何志全, 刘杨, 李泽江. 大型民用飞机缝翼全尺寸静力试验载荷设计[J]. 航空学报, 2019, 40(2):522197. HE Z Q, LIU Y, LI Z J. Load design for full scale static test of slat on large civil aircraft[J]. Acta Aeronautica et Astronautica Sinica, 2019, 40(2):522197(in Chinese).
[10] 张纪奎, 郦正能, 寇长河. 大展弦比复合材料机翼结构设计研究[J]. 航空学报, 2005, 26(4):450-453. ZHANG J K, LI Z N, KOU C H. Structural design of high aspect ratio composite material wing[J]. Acta Aeronautica et Astronautica Sinica, 2005, 26(4):450-453(in Chinese).
[11] 蔡立成, 钱诗梦, 汪海晋, 等. 铺放参数对复合材料厚度方向力学行为影响[J]. 航空学报, 2021, 42(2):423821. CAI L C, QIAN S M, WANG H J, et al. Effect of laying parameters on mechanical behavior of composite in thickness direction[J]. Acta Aeronautica et Astronautica Sinica, 2021, 42(2):423821(in Chinese).
[12] MOHAMED M, BRAHMA S, NING H B, et al. Development of beneficial residual stresses in glass fiber epoxy composites through fiber prestressing[J]. Journal of Reinforced Plastics and Composites, 2020, 39(13-14):487-498.
[13] 宋国莲, 郑锡涛, 刘振东, 等. 树脂传递模塑成型复合材料机翼干斑成因及控制方法[J]. 复合材料学报, 2021, 38(3):809-815. SONG G L, ZHENG X T, LIU Z D, et al. Formation and control of dry spot in resin transfer molding process of composite wings[J]. Acta Materiae Compositae Sinica, 2021, 38(3):809-815(in Chinese).
[14] 胡照会, 王荣国, 赫晓东, 等. 复合材料层板固化全过程残余应变/应力的数值模拟[J]. 航空材料学报, 2008, 28(2):55-59. HU Z H, WANG R G, HE X D, et al. Numerical simulation of residual strain/stress for composite laminate during overall curing process[J]. Journal of Aeronautical Materials, 2008, 28(2):55-59(in Chinese).
[15] DING A, LI S, WANG J. A comparison of process-induced residual stresses and distortions in composite structures with different constitutive laws[J]. Journal of Reinforced Plastics and Composites, 2016, 35:807-23.
[16] CHEN W J, ZHANG D Y. Improved prediction of residual stress induced warpage in thermoset composites using a multiscale thermo-viscoelastic processing model[J]. Composites Part A:Applied Science and Manufacturing, 2019, 126:105575.
[17] WHITE S R, HAHN H T. Process modeling of composite materials:Residual stress development during cure. part II. Experimental validation[J]. Journal of Composite Materials, 1992, 26(16):2423-2453.
[18] BOGETTI T A, GILLESPIE J W Jr. Process-induced stress and deformation in thick-section thermoset composite laminates[J]. Journal of Composite Materials, 1992, 26(5):626-660.
[19] KIM Y K, WHITE S R. Stress relaxation behavior of 3501-6 epoxy resin during cure[J]. Polymer Engineering & Science, 1996, 36(23):2852-2862.
[20] KIM Y K, WHITE S R. Process-induced stress relaxation analysis of AS4/3501-6 laminate[J]. Journal of Reinforced Plastics and Composites, 1997, 16(1):2-16.
[21] DING A X, LI S X, SUN J X, et al. A thermo-viscoelastic model of process-induced residual stresses in composite structures with considering thermal dependence[J]. Composite Structures, 2016, 136:34-43.
[22] DING A X, LI S X, WANG J H, et al. A three-dimensional thermo-viscoelastic analysis of process-induced residual stress in composite laminates[J]. Composite Structures, 2015, 129:60-69.
[23] SVANBERG J M, HOLMBERG J A. Prediction of shape distortions Part I. FE-implementation of a path dependent constitutive model[J]. Composites Part A:Applied Science and Manufacturing, 2004, 35(6):711-721.
[24] DING A X, LI S X, WANG J H, et al. A new path-dependent constitutive model predicting cure-induced distortions in composite structures[J]. Composites Part A:Applied Science and Manufacturing, 2017, 95:183-196.
[25] 冯震宙, 王新军, 王富生, 等. 朱-王-唐非线性粘弹性本构模型在有限元分析中的实现及其应用[J]. 材料科学与工程学报, 2007, 25(2):269-272. FENG Z Z, WANG X J, WANG F S, et al. Implementation and its application in finite element analysis of constitutive model for ZWT nonlinear viscoelastic material[J]. Journal of Materials Science and Engineering, 2007, 25(2):269-272(in Chinese).
[26] 刘振东, 郑锡涛, 冯雁, 等. 无人机全复合材料机翼结构设计与试验验证[J]. 复合材料学报, 2016, 33(5):1055-1063. LIU Z D, ZHENG X T, FENG Y, et al. Structural design and test verification of all-composite wing for unmanned aerial vehicle[J]. Acta Materiae Compositae Sinica, 2016, 33(5):1055-1063(in Chinese).
[27] 张驰, 郑锡涛, 刘振东. 轻型复合材料泡沫夹层机翼结构设计与分析[J]. 西北工业大学学报, 2013, 31(6):884-890. ZHANG C, ZHENG X T, LIU Z D. Design and analysis of a light composite wing with foam core sandwich structure[J]. Journal of Northwestern Polytechnical University, 2013, 31(6):884-890(in Chinese).
[28] TUTTLE M E, KOEHLER R T, KEREN D. Controlling thermal stresses in composites by means of fiber prestress[J]. Journal of Composite Materials, 1996, 30(4):486-502.
[29] 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.
[30] 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.
[31] FERNLUND G, RAHMAN N, COURDJI R, et al. Experimental and numerical study of the effect of cure cycle, tool surface, geometry, and lay-up on the dimensional fidelity of autoclave-processed composite parts[J]. Composites Part A:Applied Science and Manufacturing, 2002, 33(3):341-351.
[32] SHAH D B, PATEL K M, PATEL A I, et al. Experimental investigation on spring-back deformation during autoclave curing of parabolic antenna reflectors[J]. Composites Part A:Applied Science and Manufacturing, 2018, 115:134-146.

Options

Outlines

模态框（Modal）标题

Abstract

Cite this article

References