基于纤维级几何孪生模型的3D缝合预制体压缩变形仿真

Simulation of compression deformation for 3D stitched preforms based on fiber-level geometric twin models

  • 摘要: 3D缝合工艺可以在2D铺层织物之间引入连续增强纤维,高效的制备各类复杂外形的织物预制体,以缝合织物为增强结构制备的复合材料克服了2D复合材料层合板层间性能弱的缺点,在航空航天领域得到广泛应用。然而,在3D缝合复合材料的成型过程中,预制体的压实变形是不可避免的,这使得缝合纤维结构极其复杂,对复合材料的微细观建模和力学性能分析带来极大的挑战。本文通过“四步法”建模技术模拟织物铺层的缝合成型过程,建立3D缝合预制体的纤维级几何孪生模型,对预制体的压实过程进行数值仿真,分析内部纤维结构的演化过程,揭示预制体的压缩变形机制。利用Micro-CT技术对预制体样件在压缩变形前、后的微结构进行扫描测试,获取预制体内部几何结构信息,针对缝合线路径和经纬纱截面面积提出量化评价指标,验证几何孪生模型结果的准确性。结果表明,压缩前后的模型与Micro-CT图像高度一致,模型与CT扫描的缝合线路径相似度分别为88.1%、95.0%,铺层织物经、纬纱截面面积相对误差均在5%以内。本文研究成果为3D缝合复合材料的结构设计和力学性能仿真分析提供了理论基础。

     

    Abstract: The 3D stitching process enables the introduction of continuous reinforcing fibers between 2D layered fabrics, allowing the efficient fabrication of various complex-shaped fabric preforms. Composites reinforced with stitched fabrics overcome the weak interlaminar performance of 2D composite laminates and are widely used in the aerospace industry. However, during the forming process of 3D stitched composites, compaction deformation of the preform is inevitable, resulting in highly complex fiber architectures. This poses significant challenges for micro- and meso-scale modeling and mechanical property analysis of the composites. In this study, the "four-step" modeling technique is employed to simulate the stitching process of fabric layers and establish a fiber-level geometric twin model of the 3D stitched preform. Numerical simulations of the preform compaction process are conducted to analyze the evolution of the internal fiber architecture and reveal the compression deformation mechanisms. Micro-CT technology is used to scan the microstructure of the preform samples before and after compression, providing internal geometric information. Quantitative evaluation metrics for the stitching yarn path and cross-sectional areas of warp and weft yarns are proposed to validate the accuracy of the geometric twin model. The results demonstrate high consistency between the model and Micro-CT images before and after compression, with similarity rates of 88.1% and 95.0% for the stitching yarn paths, and relative errors within 5% for the cross-sectional areas of the warp and weft yarns in the layered fabric. The findings of this study provide a theoretical foundation for the structural design and mechanical performance simulation of 3D stitched composites.

     

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