碳纤维薄壁构件固化回弹对力学性能影响及顺序耦合模型

Effects of cure-induced spring-in on mechanical performance of carbon fiber thin-walled structures and development of a sequentially coupled model

  • 摘要: 针对热固性碳纤维复合材料薄壁构件固化成型分析与后续力学性能预测相互分离,难以完整反映固化历史对结构承载及损伤失效影响的问题,本文以T700碳纤维/环氧树脂预浸料平板和V型薄壁构件为研究对象,建立了成型工艺-力学性能顺序耦合数值模型。通过差示扫描量热、热膨胀及层内外力学性能试验获得固化分析与渐进损伤分析所需的主要材料参数;制备0°铺层和(0°/90°)5s对称铺层试样,开展固化回弹测量、平板三点弯曲以及V型构件三点弯曲、四点弯曲和悬臂支撑弯曲试验。模型首先计算固化过程中的温度场、固化度场、化学收缩、回弹变形及非均匀残余应力场,随后将固化变形后的有限元网格和残余应力场分别作为初始几何状态和初始应力状态,单向传递至后续弯曲分析。在此基础上,集成3D Hashin损伤起始准则、基于临界断裂能的层内损伤演化模型及层间粘聚损伤模型,形成固化历史驱动的层内-层间协同渐进损伤分析框架。结果表明,0°铺层和(0°/90°)5s对称铺层V型构件的平均回弹角分别为0.638°和1.961°,相应数值预测误差分别为10.14%和8.79%。在平板三点弯曲分析中,考虑固化残余应力后,模型力学评价指标的最大相对误差较未考虑残余应力模型降低10.93个百分点;在V型构件三种弯曲工况下,预测结果与试验结果的最大相对误差为15.7%,且能够较好预测损伤萌生位置、分层扩展区域及宏观失效模式。扫描电子显微镜(Scanning electron microscopy,SEM)观察表明,交叉铺层试样断口中存在明显的树脂撕裂和分叉,分层扩展路径较为曲折;0°铺层试样断口相对平整,裂纹主要沿层间树脂富集区或纤维-基体界面定向扩展。研究结果表明,固化后的变形构型与残余应力状态共同影响薄壁构件的载荷传递和损伤演化,所建立的顺序耦合数值模型可为复合材料薄壁构件成型精度与结构性能的联合分析提供数值支撑。

     

    Abstract: To address the separation between curing-process analysis and subsequent mechanical-performance prediction for thin-walled thermosetting carbon-fiber composite components, which makes it difficult to fully account for the effects of curing history on structural load-bearing and damage behavior, a sequentially coupled numerical model linking the manufacturing process and mechanical performance was developed for T700 carbon-fiber/epoxy flat laminates and V-shaped thin-walled components. The principal material parameters required for curing and progressive-damage analyses were obtained through differential scanning calorimetry, thermal-expansion, and intra- and interlaminar mechanical tests. Flat and V-shaped specimens with 0° and (0°/90°)5s symmetric layups were manufactured. Cure-induced spring-in measurements, three-point bending tests of flat specimens, and three-point, four-point, and cantilever-supported bending tests of V-shaped specimens were conducted. The model first calculated the temperature field, degree-of-cure field, chemical shrinkage, cure-induced deformation, and nonuniform residual-stress field during curing. The cure-deformed finite element mesh and residual-stress field were then transferred unidirectionally to the subsequent bending analysis as the initial geometric configuration and initial stress state, respectively. On this basis, the 3D Hashin damage-initiation criterion, a fracture-energy-based intralaminar damage-evolution model, and an interlaminar cohesive damage model were integrated to establish a curing-history-driven framework for coupled intralaminar and interlaminar progressive-damage analysis. The measured mean spring-in angles of the 0° and (0°/90°)5s V-shaped components were 0.638° and 1.961°, respectively, with corresponding numerical prediction errors of 10.14% and 8.79%. In the three-point bending analysis of the flat specimens, incorporating the curing residual stresses reduced the maximum relative error of the evaluated mechanical-performance metrics by 10.93 percentage points compared with the model excluding residual stresses. For the three bending configurations of the V-shaped components, the maximum relative error between the numerical and experimental results was 15.7%, and the model satisfactorily predicted the locations of damage initiation, the regions of delamination propagation, and the macroscopic failure modes. Scanning electron microscopy (SEM) revealed pronounced resin tearing and crack branching in the cross-ply specimens, resulting in relatively tortuous delamination paths. In contrast, the fracture surfaces of the 0° specimens were comparatively smooth, and cracks propagated preferentially along interlaminar resin-rich regions or fiber–matrix interfaces. These results demonstrate that the cure-deformed configuration and residual-stress state jointly affect load transfer and damage evolution in thin-walled composite components. The proposed sequentially coupled model provides a numerical basis for the integrated analysis of manufacturing accuracy and structural performance.

     

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