变厚度树脂基复合材料构件固化变形数值模拟与影响因素分析

Numerical simulation and influence factors analysis of cure-induced distortions in resin matrix composites with variable thickness

  • 摘要: 通过层间丢层形成的变厚度树脂基复合材料构件具有减材减重、可刚性裁剪等优点,常应用于机翼结构等重要位置。但层间丢层会导致构件内部的不连续性,并使构件在固化后产生不均匀残余应力,脱模后发生复杂固化变形。针对变厚度复合材料构件的固化变形预测问题,现有研究多采用等效材料性能参数的建模方法,尚未考虑其树脂口袋等结构特点。本文基于分层建模方法,在丢层位置引入树脂口袋结构,建立了变厚度构件固化变形数值仿真模型。通过与传统等效建模方法、传统分层建模方法及实验的结果比较,本文模型最大翘曲变形模拟值的误差与实验值误差仅为1.01×10−2 mm,且变形趋势一致,验证了模型的有效性和准确性。并分析了不同丢层方式、过渡区斜率、厚薄比对变厚度构件固化变形的影响规律,其中离散丢层的构件变形最小,重叠丢层的构件变形最大,且增加过渡区斜率和降低厚薄比可以有效降低其翘曲变形。

     

    Abstract: The carbon fiber reinforced polymer (CFRP) composite parts with variable thickness possessed the advantages of material saving, weight reduction, and elastic tailoring properties, and were often used in important application such as wing structures. However, dropping-off plies between layers caused a discontinuity inside the part. Therefore, uneven residual stress could be generated after the curing, and the complex cure-induced distortion (CID) appeared after demolding. For the prediction of the CID of CFRP parts with variable thickness, the existing research mainly adopted the modeling method of equivalent material parameters, without considering the structural characteristics of the resin pocket. In this paper, based on the laminated modeling method, the resin pocket structure was introduced at the dropping-off plies position, and the numerical simulation model of the CID was established. Compared with the results of the traditional equivalent modeling method, the traditional laminated modeling method and experiment, it is proved that the proposed model has the preferable accuracy, the error of the simulated CID is only 1.01×10−2 mm compared with the experimental result, and the deformation trend is consistent. The influence of different ply drop-off patterns, taper section slopes, and thickness-to-thin ratios on the CID was analyzed. The part with a dispersed ply drop-off pattern presents the smallest CID, and the part with the overlapped ply drop-off pattern has the largest CID. Increasing the taper section slope and reducing the thickness ratio can effectively reduce the warpage.

     

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