树脂传递模塑成型复合材料机翼干斑成因及控制方法

宋国莲; 郑锡涛; 刘振东; 陈牛

doi:10.13801/j.cnki.fhclxb.20201030.003

树脂传递模塑成型复合材料机翼干斑成因及控制方法

doi: 10.13801/j.cnki.fhclxb.20201030.003

西北工业大学　航空学院　飞行器复合材料研究所，西安 710072

详细信息

通讯作者:
郑锡涛，博士，教授，博士生导师，研究方向为复合材料力学性能及宏细观分析 E-mail：zhengxt@nwpu.edu.cn

中图分类号: TB332
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出版历程
- 收稿日期: 2020-08-03
- 录用日期: 2020-10-26
- 网络出版日期: 2020-10-30
- 刊出日期: 2021-03-15

Formation and control of dry spot in resin transfer molding process of composite wings

Institute of Aircraft Composite Structures, School of Aeronautics, Northwestern Polytechnical University, Xi’an 710072, China

摘要

摘要: 基于树脂传递模塑成型(RTM)工艺制作了整体成型的复合材料机翼，并针对机翼出现的干斑缺陷，采用PAM-RTM软件对干斑的成因进行分析，一方面由于上下翼面和前缘交接区域的纤维体积分数较高，导致该区域的树脂渗透率低于其他区域，从而出现包络现象，形成干斑；另一方面由于边缘效应的影响，使机翼内产生树脂快速流动通道，造成气泡包裹形成干斑。提出了有效减小干斑缺陷的控制方法，即设计两种改进的注胶方案来减小干斑区域。通过对比发现，前缘线注射方式产生的干斑区域明显较小，但注胶时间增加；通过提高树脂注射温度可降低树脂黏度，从而减少充模时间，同时通过控制出胶口的开闭可进一步减少注胶时间。
- 复合材料机翼 /
- 干斑 /
- 纤维体积密度 /
- 注胶方式 /
- 工艺参数
Abstract: Based on resin transfer molding (RTM) process, a composite wing was fabricated. Aiming at the dry spot defect of the wing, PAM-RTM software was used to analyze the formation of dry spot. Because of the high volume fraction of fibers in the junction area of upper and lower wings and leading edges, the resin permeability in this area was lower than that in other areas, thus the envelope phenomenon appeared and the dry spot was formed. Two kinds of improved injection ways were designed to reduce the dry spot area. By comparison, it is found that the dry spot area produced by the front line injection method is significantly smaller, but the injection time increases. The resin viscosity can be reduced by increasing the injection temperature, thus the filling time is reduced. At the same time, the injection time can be further reduced by controlling the opening and closing of the outlet.
- composite wing /
- dry spot /
- fiber bulk density /
- injection way /
- process parameters

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图 1 模具实物图片

Figure 1. Photograph of mold

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图 2 三角区示意图

Figure 2. Diagram of triangle area

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图 3 机翼干斑缺陷

Figure 3. Dry spot defect of wing

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图 4 上下翼面和前缘交接处不同渗透率时树脂流动前锋

Figure 4. Resin flow front at different penetration rates between upper and lower airfoil and leading edge

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图 5 上下翼面和前缘交接处不同渗透率时树脂充模时间

Figure 5. Resin filling time at different penetration rates between upper and lower airfoil and leading edge

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图 6 树脂快速流动通道示意图

Figure 6. Diagram of resin fast runner

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图 7 无边缘效应的树脂充模时间

Figure 7. Resin filling time without edge effect

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图 8 有边缘效应的树脂充模时间

Figure 8. Resin filling time with edge effect

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图 9 三种注射方式和注口位置

Figure 9. Three injection ways and positions

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图 10 不同注射方式树脂充模时间

Figure 10. Resin filling time of different injection ways

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图 12 P=0.4 MPa时的树脂充模时间

Figure 12. Resin filling time at P=0.4 MPa

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图 11 $\eta {\rm{ = }}0.4\;{\rm{Pa }}\cdot {\rm{s}}$时的树脂充模时间

Figure 11. Resin filling time at $\eta {\rm{ = }}0.4\;{\rm{Pa}} \cdot {\rm{s}}$

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图 13 关闭10号和11号出胶口树脂充模时间

Figure 13. Resin filling time after closing No.10 and No.11 vent

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表 1 充模过程树脂模拟前处理步骤

Table 1. Pretreatment of resin flow modeling.

Pretreatment category	Pretreatment item	Main content
Meshing	Create geometric model	Create the geometric model with full scale part dimensions.
	Simplify geometric model	Simplify geometric model by neglecting the unnecessary details to improve the solving efficiency.
	Assign mesh type	Select a proper mesh type according to analysis requirements.
	Meshing	Discrete the geometric model with selected mesh type.
Assign material property	Create zones	Create zones by material setup.
	Define preform properties	Set properties for preforms, such as permeability, etc.
	Define resin properties	Set properties for resin, such as viscosity, resin flow rate, etc.
Create loads and boundary condition	Define gravity vector	Assign gravity vector for the parts.
	Create boundary conditions for injections and vents	Create boundary conditions for injection and vent, such as inject pressure, flow rate, etc.
	Set up analysis limitations	Set up analysis limitations, such as the maximum pressure limitation, etc.
Create virtual sensor	Define sensor location and monitored objects	Create sensors for key points in order to record necessary data.

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表 2 三种注射方式

Table 2. Three different injection ways

Scheme	Injection port	Vent
Original scheme	Trailing edge	1, 2, 3, 4, 5
Scheme 1	Trailing edge	1, 2, 4, 5, 6, 7
Scheme 2	Leading edge	1, 5, 8, 9, 10, 11

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表 3 三种注射方式干斑大小和充模时间对比

Table 3. Comparison of three injection ways for size of dry spot and filling time

Scheme	Dry spot (upper wing)	Filling time/s
Original scheme	191 elements	1330
Scheme 1	136 elements	1250
Scheme 2	38 elements	2880

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