复合材料结构斜挖补胶接修复形状优化

Shape optimization of scarf patch adhesive repairs for composite structures

  • 摘要: 为提高复合材料层合板损伤后的修复性能,针对胶接斜接挖补修复结构开展参数优化研究。建立包含母板、胶层和补片的复合材料层合板的挖补修复三维有限元模型,采用编译VUMAT子程序,结合3D Hashin失效准则与内聚力单元法,对复合材料层合板挖补修复结构的拉伸损伤演化过程进行模拟,并通过文献试验结果对模型可靠性进行验证。利用此方法,进一步分析胶层厚度、斜接角度及补片形状与尺寸比例对修复结构力学性能的影响规律及优化方法。结果表明:建立的有限元模型能够较好预测修复结构的极限载荷,计算结果与试验误差在5%以内;随着胶层厚度增加,胶层应力集中程度增强,修复结构极限强度逐渐降低,综合考虑力学性能与加工可行性,胶层厚度取0.15 mm较为合理。斜接角度增大会导致界面应力集中加剧,使修复结构承载能力下降,适当减小斜接角有利于提高修复强度,但需要结合工程实际具体考虑。补片形状及尺寸比例对修复性能影响显著,各形状补片的强度恢复率随着尺寸比例的增大而增大。其中菱形补片表现出更优的强度恢复效果,在相同尺寸比例下不仅强度恢复率最高,同时材料去除量明显减少。

     

    Abstract: To improve the repair performance of damaged composite laminates, a parametric optimization study was conducted on bonded scarf patch repair structures. A three-dimensional finite element model of a repaired composite laminate, including the parent laminate, adhesive layer and patch, was established. The tensile damage evolution of the scarf-repaired composite laminate was simulated using a compiled VUMAT subroutine combined with the three-dimensional Hashin failure criterion and cohesive zone method, and the reliability of the model was validated by comparison with experimental results reported in the literature. Based on this method, the effects of adhesive layer thickness, scarf angle, patch shape and size ratio on the mechanical properties of the repaired structure were further analyzed. The results show that the established finite element model can accurately predict the ultimate load of the repaired structure, with an error of less than 5% compared with the experimental results. With increasing adhesive layer thickness, the stress concentration in the adhesive layer becomes more pronounced, resulting in a gradual decrease in the ultimate strength of the repaired structure. Considering both mechanical performance and manufacturing feasibility, an adhesive layer thickness of 0.15 mm is considered reasonable. Increasing the scarf angle aggravates interfacial stress concentration and reduces the load-carrying capacity of the repaired structure; therefore, appropriately reducing the scarf angle is beneficial for improving the repair strength, while practical engineering conditions should also be considered. Patch shape and size ratio have significant effects on the repair performance, and the strength recovery rate of each patch type increases with increasing size ratio. Among the investigated patch shapes, the diamond-shaped patch exhibits better strength recovery. At the same size ratio, it achieves the highest strength recovery rate while significantly reducing the volume of removed material.

     

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