基于三维缠绕技术的复杂构件全场纤维轨迹运动仿真及分布验证

Full-field fiber trajectory motion simulation and distribution verification of complex components based on three-dimensional winding technology

  • 摘要: 三维缠绕技术是一种新兴的复合材料预成型体制造技术,可以通过机器人辅助缠绕解决复杂芯模大角度纤维铺放难题,在一定长度内对任意几何形状芯模做环形缠绕。但是三维缠绕的控制方式还不成熟,对异型芯模的缠绕轨迹较为复杂,所得的纤维轨迹也难以预测。经过对三维缠绕纤维沉积过程的研究,采用运动学仿真法建立三维缠绕仿真模型,实现对三维缠绕纤维轨迹的快速预测。首先对异型芯模进行网格重构,提升了仿真的精度;然后利用空间离散点位模拟围绕复杂芯模时丝嘴的运动轨迹;最后利用纤维沉积机制作为判据,实现仿真纤维轨迹的迭代更新。三维缠绕仿真模型有两个主要输入参数:旋转环步进距离与旋转环偏转角度。通过现场试验验证,步进距离增大时,芯模的面密度会稳定降低,旋转环的动态偏转也会直接影响到弯曲芯模内外侧纤维轨迹。对直芯模进行运动学仿真所得试验结果与纤维沉积理论计算值对比,误差小于0.2%。理论与实践相结合的研究证明了运动学仿真法对三维缠绕技术仿真的可靠性与准确性。

     

    Abstract: As an emerging composite preform manufacturing technology, three-dimensional winding technology can solve the problem of large-angle fiber placement for complex core molds and make circular winding for core molds with arbitrary shapes within a certain length by robot-assisted winding. However, the control method of 3D winding is still immature, the winding trajectory of the shaped core mold is complicated, and the resulting fiber structure is difficult to predict. After the study of 3D winding fiber deposition process, the kinematic simulation method was used to establish a 3D winding simulation model to realize the fast prediction of 3D winding fiber structure. Firstly, the mesh reconstruction of the shaped mandrel was carried out to improve the accuracy of the simulation; then the spatial discrete point positions were used to simulate the motion trajectory of the filament nozzle around the complex mandrel, and finally the fiber deposition mechanism was used as a criterion to achieve the iterative updating of the simulated fiber structure. The 3D winding simulation model has two main control parameters: the step and the deflection angle of the rotary head. It is verified through experiments that the surface density of the mandrel decreases when the step increases, and the dynamic deflection of the rotary head directly affects the inner and outer fiber structure of the curved mandrel. The experiment results obtained from the simulation of the straight mandrel are compared with the theoretically calculated values, and the error is less than 0.2%. The reliability and accuracy of the kinematic simulation method for the simulation of 3D winding technology is proved by the combination of theoretical and practical research.

     

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