Mold filling process and simulation of sandwich composites with damping layer
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摘要: 在复合材料中引入黏弹性阻尼层是改善复合材料结构振动特性的有效方法。针对穿孔硅橡胶夹芯复合材料的真空辅助树脂传递工艺(VARTM)进行了实验与仿真分析。首先采用恒压注射条件分别测试了纤维增强材料及加入导流网后的等效渗透率。然后搭建了实验室VARTM观测平台进行了充模实验，同时基于RTM-Worx软件建立了树脂充模模型。通过对比实验与仿真的树脂流动状态图及不同时刻的填充面积，验证了仿真模型的有效性。最后，探究了阻尼层穿孔列间距、行距、直径及“边缘效应”等参数对树脂充模的时间及充模过程的影响。结果表明：仿真模型能够较好预测树脂流动情况，不合理的阻尼层参数会影响树脂的流动甚至导致缺陷的产生。
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关键词:
- 真空辅助树脂传递模塑 /
- 夹芯复合材料 /
- 充模过程 /
- 渗透率 /
- 边缘效应
Abstract: Introducing viscoelastic damping layer into composites is an effective method to improve the composite structural vibration characteristics. The vacuum assisted resin transfer molding (VARTM) process of sandwich composites with perforated silicone rubber was investigated by experiment and simulation. Firstly, the equivalent permeability of fiber reinforced materials and its combination with the flow medium were tested under constant pressure injection conditions. Then, the VARTM platform was set up to observe mold filling experiment in the laboratory. The resin filling model was established based on the RTM-Worx software. The validity of the simulation model was verified by comparing the experimental resin flow diagram and the filling area with simulated results at different time. Finally, the effects of the parameters such as the spacing between columns, the row spacing, the diameter of the holes in the damping layer and the "edge effect" on the resin filling time and the filling process were discussed. The results show that the simulation model can better predict the resin flow behavior, and unreasonable parameters of damping layer can affect the resin flow and even lead to defects. -
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图 2 真空辅助树脂传递工艺(VARTM)成型实验平台
Figure 2. Vacuum assisted resin transfer molding (VARTM) process experiment platform
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图 5 含阻尼层夹芯复合材料上下面树脂流动图
Figure 5. Resin flow diagram of sandwich composites with damping layer at top and bottom surfaces
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图 6 含阻尼层夹芯复合材料树脂填充剖面示意图
Figure 6. Section diagram of sandwich composites with damping layer filled by resin
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图 7 含阻尼夹芯复合材料填充过程的实验与仿真对比
Figure 7. Experimental and simulation comparison of filling process of sandwich composites with damping layer
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图 8 含阻尼层夹芯复合材料实验和仿真树脂填充状态对比
Figure 8. Comparison of experimental and simulated resin filling state of sandwich composites with damping layer
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图 9 阻尼层穿孔间距对含阻尼层夹芯复合材料VARTM成型充模时间的影响
Figure 9. Effects of damping layer perforation spacing on filling time of VARTM sandwich composites with damping layer
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图 10 不同穿孔直径下的含阻尼层夹芯复合材料VARTM成型填充时间
Figure 10. VARTM filling time of sandwich composites with damping layer under different perforation diameters
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图 11 不同穿孔直径对含阻尼层夹芯复合材料VARTM成型树脂流动的影响
Figure 11. Effects of different perforating diameter on resin flow in VARTM sandwich composites with damping layer
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图 12 不同边缘效应的含阻尼层夹芯复合材料预成型体的填充时间
Figure 12. Filling time of preformed sandwich composites with different edge effects
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图 13 含阻尼层夹芯复合材料下层合板填充时间分布
Figure 13. Filling time distribution at bottom laminate of sandwich composites with damping layer
表 1 材料参数测试结果
Table 1 Test results of material parameters
Laminate
typeEquivalent
porosity/%Average permeability/
(10−11 m2)Length wise Kx Width wise Ky EW200 57.4 2.78 2.67 EW200+ 60.0 115 83 
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表 2 阻尼层穿孔间距对含阻尼层夹芯复合材料VARTM成型树脂流动的影响
Table 2 Effects of damping layer perforation spacing on resin flow in VARTM sandwich composites with damping layer
Process parameter Resin flow diagram at 50% filling modulus of the preform D=2 mm, C=15 mm
Change row space S
D=2 mm, S=15 mm
Change column space C
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表 3 不同穿孔直径对应的含阻尼层夹芯复合材料VARTM成型孔洞渗透率
Table 3 Permeability of VARTM sandwich composites with damping layer in different perforation diameters
Diameter/mm Porosity/mm2 0.5 3.927×10−5 1 0.0127 2 0.161 3 0.498 4 1.031 5 1.758 6 2.682 7 3.802 8 5.118
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其他类型引用(6)
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目的
在复合材料中引入粘弹性阻尼层是改善复合材料结构振动特性的有效方法。由于粘弹性阻尼层一般为疏水性材料阻碍了树脂流动容易导致缺陷产生，所以分析树脂在夹芯材料中的复杂流动行为十分重要。本文针对穿孔硅橡胶夹芯复合的真空辅助树脂传递工艺(VARTM)中树脂填充行为进行研究。
方法首先利用实验室搭建的VARTM实验平台在恒压注射的条件下分别测试了纤维增强材料以及加入导流网后的等效渗透率。其次，基于仿真软件RTM-Worx，采用控制体/有限元(CV/FEM)方法对树脂流动前沿追踪，建立了含阻尼层夹芯复合材料VARTM成型的充模模型。通过对比实验与仿真的树脂流动状态图及不同时刻的填充面积，验证了仿真模型的有效性。进而，探究了阻尼层穿孔间距、行距、直径及“边缘效应”等参数对树脂充模的时间及流动过程的影响。
结果从树脂充模实验可以看出树脂在含阻尼层夹芯复合材料充模过程的流动行为具体表现为：树脂沿平面方向线性扩展快速充满整个导流网，同时导流网面内的树脂沿厚度方向渗透浸润上层合板，接着树脂浸透穿过阻尼层孔洞，然后以孔洞为中心向四周浸润扩散，下层合板的流动前沿呈现一定的锯齿状。对比了实验和仿真充模的树脂流动状态及不同时刻的填充面积。树脂填充流动的形式和填充速率基本一致相同，上层面板树脂流动前沿成线性向前扩展，下层纤维面板中树脂流动前沿呈一定的锯齿状；且上、下层合板的仿真与实验填充速率变化趋势基本一致，验证了模型的有效性。对不同阻尼层穿孔参数预成型体进行树脂充填过程的模拟仿真，得出穿孔间距、行距、直径及“边缘效应”等参数对预成型体树脂充填影响规律。对比分析模拟结果得出：随穿孔间距变大，下层合板树脂流动前沿的锯齿状加深，树脂流动同步性变差。随穿孔行距变大，下层合板的前后两行孔洞的树脂流动前沿易形成干涉，产生包络区域，从而积聚气泡，产生成型缺陷。穿孔直径主要影响充模速率，当直径小于1mm时，充模时间急剧增加。侧流边缘效应会导致不良的树脂流动前沿，一部分树脂提前通过排气口溢出，故在下层合板靠近排气口位置易出现包络现象，增加了充模时间。
结论(1)树脂在含阻尼层夹芯复合材料充模过程中的流动行为可以分为三个阶段，树脂线性扩展填充导流介质及上层合板；树脂填充并穿透阻尼层孔洞；树脂在下层合板中以孔洞为中心向四周扩散。(2)仿真模型考虑了增强纤维和导流网的等效渗透率以及孔洞边界层的边缘效应。仿真结果与实验相比具有较好的一致性从而验证了仿真模型的有效性。(3)不同的阻尼层穿孔参数对充模过程有不同的影响：①穿孔列间距影响下层合板流动锯齿状深度，间距增大树脂流动同步性变差；②穿孔行距增加使下层合板的前后两行孔洞的树脂流动前沿形成干涉，产生包络区域，产生成型缺陷；③穿孔直径主要影响充模速率，当直径小于1mm时，影响了树脂通过孔洞流入下层合板，充模时间增加；④侧流边缘效应会导致不良的树脂流动前沿，在下层合板靠近排气口位置易出现包络现象并增加充模时间。
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随着风电叶片长度增加、柔性增大，由此引发的结构振动问题不可忽视。通过在复合材料中引入粘弹性阻尼层是改善结构振动特性的有效方法。然而，传统真空辅助树脂传递成型中阻尼层不但影响了树脂的流动和对增强纤维的浸润，降低了复合材料构件的成型效率，且极易出现制造缺陷影响结构性能。
首先采用恒压注射条件分别测试了纤维增强材料以及加入导流网后的等效渗透率,然后在实验室搭建VARTM观测平台进行了充模实验，同时基于RTM-Worx软件建立了考虑边缘效应的树脂充模仿真模型，并通过与实验结果对比流动状态与充模时间验证了模型正确性。最后仿真分析了穿孔间距、穿孔直径等对充模过程的影响：①穿孔列间距影响下层合板流动锯齿状深度，间距增大树脂流动同步性变差。②穿孔行距增加使下层合板的前后两行孔洞的树脂流动前沿形成干涉，产生包络区域，产生成型缺陷。③穿孔直径主要影响充模速率，当直径小于1mm时影响了树脂的从上层流入下层，充模时间显著增加。④侧流边缘效应会导致不良的树脂流动前沿，在下层合板靠近排气口位置易出现包络现象并增加充模时间。
不同穿孔间距对树脂流动的影响
不同穿孔间距对上下层填充时间的影响
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