面向纤维增强复合材料预成型的高保真纤维壳仿真模型

High-Fidelity Fibrous Shell for Fiber-Reinforced Composites Preforming

  • 摘要: 纤维增强复合材料预成型过程的精确仿真,是优化其制造工艺的关键。然而,其纤维结构导致的准不可延伸性和纤维间滑移等特殊变形机制,使得基于经典理论的壳单元在模拟时存在材料法线旋转预测失真、计算效率低下等问题。本文提出了专为纤维增强复合材料预成型设计的高保真纤维壳有限元模型。该模型建立了基于纤维变形物理机制的纤维壳单元,通过修正的虚功原理与运动学描述,准确再现了预成型过程中的材料法线旋转。通过引入面内弯曲变形模式,有效消除了仿真中的非物理虚假模态,显著提升了纤维取向与分布的预测精度。针对工业界常用的多铺层方向叠层,提出了均质化取向多层纤维壳策略,通过将相同纤维取向的铺层集合为单一计算层并采用主-从接触算法,在保持高精度的同时实现了计算效率的数量级提升。纤维增强材料的成型仿测对比表明,该模型在预测变形、剪切角、层间滑移等方面均展现出与实验高度一致的结果,为工业级复合材料构件的高效、高保真预成型仿真提供了可靠的解决方案。

     

    Abstract: Simulating the preforming of fiber-reinforced composites is essential for manufacturing optimization. However, classical shell elements often yield inaccurate results due to the materials' unique deformation mechanisms, such as fiber quasi-inextensibility and slippage. A high-fidelity fibrous shell element was developed to address these issues. The model incorporates a modified virtual work principle and kinematics to accurately simulate material normal rotation. In-plane bending was introduced to eliminate numerical instabilities and improve prediction accuracy. For multi-orientation laminates, a homogenized multilayer strategy was proposed, grouping plies by orientation and using a master-slave contact algorithm. This strategy maintained high accuracy while improving computational efficiency by an order of magnitude. Validation experiments confirmed the model's accuracy in predicting deformation, shear angles, and inter-ply slippage, providing an effective solution for industrial-scale composite preforming simulation.

     

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