高精度碳纤维增强树脂复合材料夹层天线面板热变形影响参数仿真与实验

吴楠; 郝旭峰; 史耀辉; 鞠博文; 钱元; 蔡登安; 周光明

doi:10.13801/j.cnki.fhclxb.20191107.002

高精度碳纤维增强树脂复合材料夹层天线面板热变形影响参数仿真与实验

doi: 10.13801/j.cnki.fhclxb.20191107.002

吴楠^1,,
郝旭峰^2,,
史耀辉^2,,
鞠博文^2,,
钱元^3,,
蔡登安^1,,
周光明^1, ,

1.
南京航空航天大学　机械结构力学及控制国家重点实验室，南京 210016
2.
上海复合材料科技有限公司，上海 201112
3.
中国科学院　紫金山天文台，南京 210008

基金项目: 南京航空航天大学（实验室）开放基金（kfjj20180107）；上海航天科技创新基金（SAST2018-071）；江苏省基础研究计划（自然科学基金）（ BK20190394）

详细信息

通讯作者:
周光明，博士，博士生导师，研究方向为先进复合材料工艺及应用　E-mail：zhougm@nuaa.edu.cn

中图分类号: TB332
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- 被引次数: 0
出版历程
- 收稿日期: 2019-08-11
- 录用日期: 2019-10-31
- 网络出版日期: 2019-11-07
- 刊出日期: 2020-07-15

Simulation and experiment on thermal deformation influence parameters of high accuracy carbon fiber reinforced plastic sandwiched antenna panels

WU Nan^1
,,
HAO Xufeng^2
,,
SHI Yaohui^2
,,
JU Bowen^2
,,
QIAN Yuan^3
,,
CAI Deng’an^1
,,
ZHOU Guangming^{1
, ,}

1.
State Key Laboratory of Mechanics and Control of Mechanical Structures, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2.
Shanghai Composite Technology Co. Ltd., Shanghai 201112, China
3.
Purple Mountain Observatory, Chinese Academy of Sciences, Nanjing 210008, China

摘要

摘要: 为满足亚毫米波、太赫兹波段等高频天线反射面的应用需求，采用附加树脂修型技术制得1米级、面形精度优于10 μm均方差(RMS)的碳纤维增强树脂(CFRP)复合材料天线面板。主要开展了针对高精度CFRP复合材料面板在极端低温环境下的热变形机制研究。根据基础材料性能测试数据，建立面板的有限元仿真模型，预测大温差工况下多结构参数面板的热变形残差，分析了影响面板热变形特性的主要因素。比较了铝蜂窝和碳管阵列夹芯两种面板结构热变形特性的差异。结果表明，碳管夹芯结构面板具备更高的比刚度和热稳定性。通过仿真结构优化给出了面板的结构设计参数，并重新试制了原型面板。采用基于高精度数字摄影测量的实验方法，对铝蜂窝和碳管阵列两种夹芯结构原型面板在低温环境下的热变形误差进行了测量，通过分析实验与仿真结果的误差来源，讨论了有限元预测方法的可行性，给出了针对高精度CFRP复合材料面板设计及工艺方法的指导意见。
- 碳纤维增强树脂(CFRP) /
- 复合材料 /
- 高精度面板 /
- 极端环境 /
- 热稳定性 /
- 摄影测量
Abstract: A one-meter-level carbon fiber reinforced plastic(CFRP) composite antenna panel with the surface error less than 10 μm root-mean-square(RMS) has been trial-produced by using additional resin modification technology to satisfy the requirements of high frequency antenna reflector in submillimeter and terahertz wave band. The thermal deformation mechanisms of the high accuracy CFRP composite panel under extreme low temperature were studied. Based on the test data of the basic material, a finite element model was established to predict the thermal deformation residual error of the the panels considering different parameters under the condition of large temperature difference. The main factors affecting the thermal deformation characteristics of the panel were analyzed. The thermal deformation characteristics of the panels with aluminum honeycomb and CFRP composite tube array cores were compared, respectively, which shows that the higher specific stiffness and thermal stability are provided by the panel structure with CFRP composite tube array core. The structural design parameters of the prototype panel were given after the structural optimization, and the prototype panels were remanufactured. The thermal deformation residual errors of prototype panels with aluminum honeycomb and CFRP composite tube array cores were measured by the experimental method of high precision photogrammetry. The guidance for the design and process of high accuracy CFRP composite sandwiched panels was provided.
- carbon fiber reinforced plastic(CFRP) /
- composite /
- high accuracy panel /
- extreme environments /
- thermal stability /
- photogrammetry

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图 1 反射器单瓣面板结构

Figure 1. Structure of single melon in reflector

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图 2 附加用于修正面形的树脂层

Figure 2. Additional resin coating replication for surface shape modification

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图 3 附加树脂修型前后的面形误差分布

Figure 3. Surface error distribution before and after additional resin coating process

RMS—Root-mean-square; f—Focus

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图 4 碳纤维增强树脂(CFRP)复合材料夹层反射面板有限元模型

Figure 4. Finite element model of carbon fiber reinforced plastic(CFRP) composite sandwiched reflector panel

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图 5 CFRP复合材料夹层天线面板蒙皮拉伸试验和压缩试验

Figure 5. Stretching test and compression test of sheet of CFRP composite sandwiched antenna panel

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图 6 铝蜂窝结构压缩试验和剪切试验

Figure 6. Compression test and shear test of aluminum honeycomb

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图 7 CFRP复合材料碳管压缩试验和双搭剪切试验

Figure 7. Compression test and double-set shear test of CFRP composite tube

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图 8 不同铺层方式、铺层角度误差和厚度的蒙皮和不同厚度的芯材对CFRP复合材料夹层天线面板仿真结果的影响

Figure 8. Effects of different modes and angle errors of lay-out and thicknesses of sheets and different thicknesses of core on simulation results of CFRP composite sandwiched antenna panel

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图 9 芯材的不同加工方式

Figure 9. Different ways of core processing

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图 10 不同种类、厚度和加工方式的芯材对CFRP复合材料夹层天线面板仿真结果的影响

Figure 10. Effects of different types, thicknesses and processing processes of core on simulation results of CFRP composite sandwiched antenna panel

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图 11 摄影测量系统

Figure 11. Photogrammetry system

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图 12 测量的重复性误差

Figure 12. Repeatability error of measurement

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图 13 原型面板及初始型面精度

Figure 13. Prototype panel and initial surface RMS

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图 14 CFRP复合材料夹层天线面板有限元模型与试验的面形误差结果比较

Figure 14. Comparison of thermal error results between finite element model and experiment for CFRP composite sandwiched antenna panel

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表 1 蒙皮及芯材的性能参数

Table 1. Property parameters of sheet and core

Property		Sheet	Aluminum honeycomb(l=4 mm/t₁=0.03 mm)	CFRP tube (r=20 mm/t₂=0.2 mm)
Elastic modulus	E₁₁/GPa	125.4	0.01	0.01
	E₂₂/GPa	10.6	0.01	0.01
	E₃₃/GPa	−	0.67	0.34
Shear modulus	G₁₂/GPa	4	0.01	0.01
	G₂₃/GPa	−	0.25	0.3
	G₁₃/GPa	−	0.15	0.3
Poisson’s ratio	μ₁₂	0.27	0.3	0.9
	μ₂₃	−	0.01	0.01
	μ₁₃	−	0.01	0.01
CTE	α₁/10⁻⁶℃⁻¹	1.8	23	2.5
	α₂/10⁻⁶℃⁻¹	−	23	2.5
	α₃/10⁻⁶℃⁻¹	−	23	2.5
Notes:CTE—Coefficient of thermal expansion; l—Length of aluminum honeycomb; t₁—Thickness of aluminum honeycomb; r—Radius of composite tube; t₂—Thickness of CFRP composite tube.

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表 2 CFRP复合材料夹层天线面板多种仿真工况的参数

Table 2. Parameters of multiple simulated conditions for CFRP composite sandwiched antenna panel

Condition	Thickness of sheets/mm	Thickness of core/mm	Lay-out of sheets	Angle error of lay-out/(°)
Ⅰ	2.4	65	Orthogonal/quasi-isotropy	−
Ⅱ	0.8–3.6	65	Orthogonal/quasi-isotropy	−
Ⅲ	2.4	35–65	Quasi-isotropy	−
Ⅳ	2.4	65	Quasi-isotropy	0–10

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表 3 芯材的仿真参数

Table 3. Parameters of core

Condition	Types of core	Thickness of core/mm	Core processing process
Ⅴ	Aluminum honeycomb/CFRP tube array	35–65	Surface machining /Surface squeeze

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表 4 原型面板的参数

Table 4. Parameters of prototype panel

Number	Thickness of sheets/mm	Types of core	Fiber volume fraction/vol%	Thickness of core/mm	Lay-out of sheetss	Core processing process
Design value	2.2	−	60/60	65	Orthogonal	Surface squeeze
A	2.5/2.2	Aluminum honeycomb	52.4/60.5	65	Orthogonal	Surface squeeze
B	2.5/2.2	CFRP tube array	51.5/62.3	65	Orthogonal	Surface squeeze

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