基于封头补强的非连续预浸带铺贴褶皱预测及形成机理分析

Prediction and formation mechanism analysis of wrinkles in discontinuous prepreg tape placement based on dome reinforcement

  • 摘要: 为实现非连续预浸带铺贴褶皱缺陷预测并揭示其内在形成机理,本文基于自动纤维铺贴(Fiber Patch Placement,FPP)技术的复合材料压力容器封头补强工艺,采用数值仿真与实验相结合的方法,聚焦铺贴角度这一关键工艺参数,对预浸带贴片铺放过程中所形成的褶皱缺陷进行研究。首先,通过单轴拉伸、偏轴拉伸、悬臂梁弯曲及探针黏性实验,系统表征了SYM38360/T700单向热固性预浸料在实际工况下的力学性能参数。基于此,构建了融合混合壳-膜单元与黏性接触的高保真有限元模型,以30°铺贴角度为例进行验证,模型预测结果与实验结果吻合良好。进一步通过变角度铺贴实验(35°~55°,间隔5°)探究了铺贴角度对褶皱缺陷的影响规律,结果表明,褶皱程度随角度变化呈现先减后增趋势,在45°时达到最优状态,此时沿纤维方向(贴片长度方向)无褶皱,垂直于纤维方向(贴片宽度方向)仅出现轻微隆起。机理分析表明,沿纤维方向褶皱主要由封头曲率突变和黏性摩擦导致的纤维方向失稳引起;垂直于纤维方向褶皱则源于曲率适应过程中产生的横向压缩应力在自由边缘诱发的面外屈曲。

     

    Abstract: To predict wrinkle defects in discontinuous prepreg tape placement and elucidate the associated formation mechanisms, this work investigates the dome reinforcement process of composite pressure vessels using Fiber Patch Placement (FPP). A combined experimental and numerical framework is established, with the placement angle treated as the key process variable. First, the material properties of SYM38360/T700 unidirectional thermoset prepreg under processing conditions are characterized through uniaxial tensile, off-axis tensile, cantilever bending, and probe tack tests. Based on the measured parameters, a high-fidelity finite element model is developed by incorporating hybrid shell–membrane elements and viscous contact. Validation at a placement angle of 30° shows good agreement between the predicted wrinkle morphology and the experimental observations. Variable-angle placement experiments are then conducted over a range of 35°-55° with an interval of 5° to evaluate the influence of placement angle on wrinkle formation. The results indicate that wrinkle severity decreases initially and then increases with increasing placement angle, with the best placement quality obtained at 45°. Under this condition, no obvious wrinkles are observed along the fiber direction, whereas only slight out-of-plane bulging appears in the transverse direction. Mechanism analysis reveals that fiber-direction wrinkles are mainly caused by instability induced by abrupt curvature variation in the dome region combined with viscous friction, while transverse wrinkles originate from out-of-plane buckling triggered by transverse compressive stresses developing near the free edges during adaptation to the curved surface.

     

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