复合材料机翼结构热校形工艺实验及数值模拟

王海雷; 刘凯; 张博明; 叶金蕊

doi:10.13801/j.cnki.fhclxb.20210202.004

复合材料机翼结构热校形工艺实验及数值模拟

doi: 10.13801/j.cnki.fhclxb.20210202.004

1.
中国航空制造技术研究院，北京 100042
2.
北京理工大学　先进结构技术研究院，北京 100081
3.
北京航空航天大学　材料科学与工程学院，北京 100191

基金项目: 国家自然科学基金青年基金(11902030)

详细信息

通讯作者:
刘凯，博士，研究方向为复合材料工艺力学　E-mail：liukai96200@yeah.net

中图分类号: TB332
计量
- 文章访问数: 926
- HTML全文浏览量: 287
- PDF下载量: 93
- 被引次数: 0
出版历程
- 收稿日期: 2020-12-03
- 录用日期: 2021-01-20
- 网络出版日期: 2021-02-02
- 刊出日期: 2021-05-01

Simulation and experimental studies of hot sizing process for composite wing structures

1.
AVIC Manufacturing Technology Institute, Beijing 100042, China
2.
Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing 100081, China
3.
School of Materials Science and Engineering, Beihang University, Beijing 100191, China

摘要

摘要: 纤维增强树脂基复合材料机翼结构复杂，往往存在明显的固化变形现象，严重影响机翼的装配和气动特性。本研究目的在于建立大型复合材料复杂结构的热校形工艺方法，解决复合材料机翼制造的变形控制问题。针对复合材料机翼的固化变形特点，设计了新的热校形夹具工装。在评价复合材料应力松弛特性的基础上，建立了大型复合材料机翼结构热校形工艺的有限元模拟方法，实现了对热校形后机翼结构残余变形的有效预报，分析了校形载荷、校形温度等关键工艺参数对校形效果的影响规律，形成优化的热校形工艺方案。模拟及实验结果表明，复合材料热校形工艺可以适用于大型复杂结构，复合材料机翼89.5%的固化变形被热校形工艺的残余变形抵消，达到机翼的装配和气动外形要求。
- 复合材料 /
- 热校形 /
- 变形控制 /
- 应力松弛 /
- 有限元分析
Abstract: Obvious process induced distortions usually take place in complex wing structures made of polymer-matrix composites. This leads to problems in the assembly and aerodynamics performance of composite wings. The objective of the present work is to develop a hot sizing process for large and complex composite structures, to solve the distortion control problem of composite wings. New sizing tools were designed according to the process induced distortions of wings, to carry out hot sizing experiments. A finite element simulation method was built up to predict the final shape of wings after hot sizing, based on characterizing the stress relaxation property of composites. The effects of process parameters were analyzed including temperature, sizing loads, et al, in order to optimize the hot sizing scheme. The simulation and experiments results show that hot sizing process is valid for large and complex composite structures. 89.5% of the process induced distortions of the composite wing structures is compensated by the hot sizing process, meeting the geometry requirements for assembly and aerodynamic characteristics.
- composite /
- hot sizing /
- distortion control /
- stress relaxation /
- finite element analysis

HTML全文

图 1 T300碳纤维/环氧树脂复合材料应力松弛过程中松弛模量的变化

Figure 1. Evolution of relaxation modulus of T300 carbon fiber/epoxy composites during stress relation

下载: 全尺寸图片幻灯片

图 2 T300碳纤维/环氧树脂复合材料机翼外形及尺寸(a)、机翼根部截面尺寸及形状(b)、机翼端部尺寸及形状(c)、机翼有限元模型及不同铺层区域分布(d)

Figure 2. Skeleton of wing (a), cross section of wing at end (b), cross section of wing at base (c), mesh of wing and three regions according to lay-ups (d) of T300 carbon fiber/epoxy composite

下载: 全尺寸图片幻灯片

图 3 树脂传递模塑(RTM)成型后复合材料机翼固化变形情况

Figure 3. Experimental process induced distortions of wings after resin transfer molding (RTM) process

α_PID—Torsion angle; ΔH—Height difference between front and rear edges

下载: 全尺寸图片幻灯片

图 4 热校形夹具工装(a)、夹头1示意图(b)、夹头2~5示意图(c)

Figure 4. Hot sizing tools (a), clamp 1 (b), clamp 2–5 (c)

下载: 全尺寸图片幻灯片

图 5 校形载荷下T300碳纤维/环氧树脂复合材料机翼结构的位移及应力分布

Figure 5. Displacement and stress distribution of wing of T300 carbon fiber/epoxy composites under sizing load

U₂—Displacement; S₁₁—Stresse in 1st direction; S₂₂—Stresse in 2nd direction; S₁₂—In-plane shear stress

下载: 全尺寸图片幻灯片

图 6 应力松弛后T300碳纤维/环氧树脂复合材料机翼结构的应力分布

Figure 6. Stress distribution of wing of T300 carbon fiber/epoxy composites after stress relaxation

下载: 全尺寸图片幻灯片

图 7 热校形后T300碳纤维/环氧树脂复合材料机翼结构的残余变形及应力分布

Figure 7. Final displacement and stress distribution of wing of T300 carbon fiber/epoxy composites after hot sizing

下载: 全尺寸图片幻灯片

图 8 不同校形载荷L_s (a)、不同夹头位置(b)、不同夹头数目(c)、不同校形温度T_s (d)下机翼结构热校形工艺模拟结果

Figure 8. Simulation results with different sizing loads L_s (a), different clamp locations (b), different amounts of clamps (c) and different hot sizing temperatures T_s (d)

Δα—Change of torsion angle

下载: 全尺寸图片幻灯片

图 9 热校形前后T300碳纤维/环氧树脂复合材料机翼扭转角度(a)、对扭转角变化Δα和最终位移ΔU的模拟与实验结果进行对比(b)

Figure 9. Experimental torsion angles before and after hot sizing (a), comparison between simulation and experimental results on change of torsion angles Δα and final displacement ΔU (b) of wing of T300 carbon fiber/epoxy composites

下载: 全尺寸图片幻灯片

表 1 T300碳纤维/环氧树脂复合材料力学参数

Table 1. Mechanical parameters of T300 carbon fiber/epoxy composite

Parameter	E₁₁/GPa	E₂₂/GPa	μ₁₂	G₁₂/GPa	G₁₃/GPa	G₂₃/GPa
Value	136	9.04	0.34	3.87	3.87	3.22
Notes: E₁₁, E₂₂—Modulus in 1st direction and 2nd direction, respectively; μ₁₂—Poisson’s ratio in 12 direction; G₁₂, G₁₃, G₂₃—Shear modulus in 12 direction, 13 direction and 23 direction, respectively.

下载: 导出CSV

表 2 机翼结构不同区域铺层情况

Table 2. Stacking sequences of plies in wing

Region	Skin area 1	Skin area 2	Beam
Stiffened	[(45/0₂/−45)₂/(45/0₃/−45/0₃)₂]	[(45/−45/0₃/45/−45/0)₂/(45/0₂/−45/0₃/45/0₂/ −45/0)_S/(45/0/0/−45)₂/(45/0₃/−45/0₃)₂]	[(45/0₂/−45/0₃/45/0₂/−45/90)_S/45/ −45/0₃/45/−45/0]₂
Transition	[45/0₂/−45/(45/0₃/−45/0₃)₂]	[45/−45/0₃/45/−45/0/(45/0₂/−45/0₃/45/0₂/ −45/90)_S/45/0₂/−45/(45/0₃/−45/0₃)₂]	[45/0₂/−45/0₃/45/0₂/−45/90]_SS
Thin-walled	[45/0₃/−45/0₃]₂	[(45/0₂/−45/0/₃/45/0₂/−45/90)_S/(45/0₃/−45/0₃)₂]	[(45/0₂/−45/0₃/45/0₂/−45/90)_S/45/ −45/0₃/45/−45/0]

下载: 导出CSV

表 3 校形载荷L_s和校形温度T_s对热校形工艺回弹率S的影响

Table 3. Effect of hot sizing temperature T_s and sizing loads L_s on spring back rate S

L_s/(°)	T_s/°C	Δα/(°)	S/%
−2.8	80	−0.19	93.0
−5.6	80	−0.38	93.1
−8.4	80	−0.56	93.3
−11.2	80	−0.71	93.6
−5.6	80	−0.38	93.2
−5.6	90	−0.63	88.7
−5.6	100	−0.86	84.6

下载: 导出CSV

参考文献(22)

[1]	岳广全. 整体化复合材料壁板结构固化变形模拟及控制方法研究[D]. 哈尔滨: 哈尔滨工业大学, 2010. YUE Guangquan. Study on simulation and control method of cure-induced deformation for integrated composite panel[D]. Harbin: Harbin Institute of Technology, 2010(in Chinese).
[2]	李君, 姚学锋, 刘应华, 等. 复合材料T 型整体化结构固化翘曲变形模拟[J]. 复合材料学报, 2009, 26(1):156-161. doi: 10.3321/j.issn:1000-3851.2009.01.027 LI Jun, YAO Xuefeng, LIU Yinghua, et al. Simulation on curing warpage deformation of composite T-shaped integrated structure[J]. Acta Materiae Compositae Sinica,2009,26(1):156-161(in Chinese). doi: 10.3321/j.issn:1000-3851.2009.01.027
[3]	江天, 徐吉峰, 刘卫平, 等. 整体化复合材料结构分阶段固化变形预报方法及其实验验证[J]. 复合材料学报, 2013, 30(5):61-66. doi: 10.3969/j.issn.1000-3851.2013.05.010 JIANG Tian, XU Jifeng, LIU Weiping, et al. Simulation and verification of cure-induced deformation by stages for integrated composite structure[J]. Acta Materiae Compositae Sinica,2013,30(5):61-66(in Chinese). doi: 10.3969/j.issn.1000-3851.2013.05.010
[4]	WU B, LAN F, PARDOEN T, et al. Tooling geometry optimization for compensation of cure-induced distortions of a curved carbon/epoxy C-spar[J]. Composites Part A: Applied Science and Manufacturing, 2014, 56: 27-35.
[5]	LIU K, YE J, TANG Z, et al. Simulation and verification of machining deformation for composite materials[J]. Journal of Wuhan University of Technology (Materials Science Edition), 2014, 29(5): 917-922.
[6]	DING A, LI S, WANG J, et al. A three-dimensional thermo-viscoelastic analysis of process-induced residual stress in composite laminates[J]. Composite Structure,2015,129:60-69.
[7]	ISMET B, KENAN C, NURI E, et al. A review on the mechanical modeling of composite manufacturing processes[J]. Archives of Computational Methods in Engineering,2016,24(2):1-31.
[8]	BRAUNER C, BAUER S, HERRMANN A S. Analysing process-induced deformation and stresses using a simulated manufacturing process for composite multispar flaps[J]. Journal of Composite Materials,2015,49(4):387-402. doi: 10.1177/0021998313519281
[9]	张纪奎, 郦正能, 关志东, 等. 热固性复合材料固化过程三维有限元模拟和变形预测[J]. 复合材料学报, 2009, 26(1):174-178. doi: 10.3321/j.issn:1000-3851.2009.01.030 ZHANG Jikui, LI Zhengneng, GUAN Zhidong, et al. Three-dimensional finite element simulation and prediction for process-induced deformation of thermoset composites[J]. Acta Materiae Compositae Sinica,2009,26(1):174-178(in Chinese). doi: 10.3321/j.issn:1000-3851.2009.01.030
[10]	LI D, LI X, DAI J. Process modelling of curing process-induced internal stress and deformation of composite laminate structure with elastic and viscoelastic models[J]. Applied Composite Materials,2018,25(3):527-544. doi: 10.1007/s10443-017-9633-5
[11]	HO K C, LIN J, DEAN T A. Modelling of springback in creep forming thick aluminum sheets[J]. International Journal of Plasticity. 2004, 20(4-5): 733-751.
[12]	SHONG Z C, LING Z R, PEKLENIK J. A study of the hot sizing and high temperature mechanical behaviour for titanium alloy sheet[J]. CIRP Annals, 1983, 32(1): 161-165.
[13]	陈春奎, 黄永坚, 王以璠, 等. 钛和钛合金钣金零件的热校形[J]. 材料科学与工艺, 1985, 21(2):93-104. CHEN Chunkui, HUANG Yongjian, PAN Yifan, et al. Hot sizing on Ti alloy and Ti parts[J]. Material Science and Engineering,1985,21(2):93-104(in Chinese).
[14]	ZHAN L, LIN J, DEAN T A. A review of the development of creep age forming: Experimentation, modeling and applications[J]. International Journal of Machine Tools & Manufacture, 2011, 51(1): 1-17.
[15]	LIN J, HO K C, DEAN T A. An integrated process for modeling of precipitation hardening and spring back in creep age forming[J]. International Journal of Machine Tools & Manufacture, 2006, 46(11): 1266 -1270.
[16]	HO K C, LIN J, DEAN T A. Constitutive modelling of primary creep for age forming an aluminium alloy[J]. Journal of Materials Processing Technology, 2004, 153-154: 122 -127.
[17]	AARON C L, SHI Z, YANG H, et al. Creep-age forming AA2219 plates with different stiffener designs and pre-form age conditions: Experimental and finite element studies[J]. Journal of Materials Processing Technology, 2015, 219: 155-163.
[18]	LEI C, YANG H, LI H, et al. Dependence of creep age formability on initial temper of an Al-Zn-Mg-Cu alloy[J]. Chinese Journal of Aeronautics,2016,29(5):1445-1454. doi: 10.1016/j.cja.2016.04.022
[19]	LIU K, YE J, ZHANG B, 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.
[20]	ASTM International. Standard test methods for tensile, compressive, and flexural creep and creep-rupture of plastics: ASTM D2990—17[S]. West Conshohocken: ASTM International, 2017.
[21]	SUN C T, CHEN J L. A simple flow rule for characterizing nonlinear behavior of fiber composites[J]. Journal of Composite Materials, 1989, 23(10): 1009–1020.
[22]	LI H, ZHANG B. A new viscoelastic model based on generalized method of cells for fiber-reinforced composites[J]. International Journal of Plasticity, 2015, 65: 22-32.