大型复合材料航空件固化成型模具技术研究与应用进展

肖遥; 李东升; 吉康; 李勇

doi:10.13801/j.cnki.fhclxb.20210830.001

大型复合材料航空件固化成型模具技术研究与应用进展

doi: 10.13801/j.cnki.fhclxb.20210830.001

肖遥¹,
李东升¹,
吉康²,
李勇^1, ,

1.
北京航空航天大学　机械工程及自动化学院，北京 100191
2.
北京宇航系统工程研究所，北京 100076

基金项目: 中央高校基本科研项目(YWF-20-BJ-J-1016；YWF-21-BJ-J-1017)

详细信息

通讯作者:
李勇，博士，教授，博士生导师，研究方向为先进复合材料模具设计与制造　E-mail：liyong19@buaa.edu.cn

中图分类号: TB332
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- 被引次数: 0
出版历程
- 收稿日期: 2021-06-25
- 修回日期: 2021-07-25
- 录用日期: 2021-08-20
- 网络出版日期: 2021-08-30
- 刊出日期: 2021-03-01

Research and application progress of curing tooling technology for large composite aeronautical components

XIAO Yao¹,
LI Dongsheng¹,
JI Kang²,
LI Yong^{1
, ,}

1.
School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China
2.
Beijing Institute of Astronautical Systems Engineering, Beijing 100076, China

摘要

摘要: 固化成型模具是诱导热固性树脂基复合材料构件制造变形的关键因素之一。大型航空用复合材料构件整体化、批量化及高精度高性能发展趋势对固化用模具提出了更高的精度及寿命要求，推动了模具材料、设计及制造工艺方面的新发展，但目前相关研究尚缺乏系统梳理。因此，针对航空用大型复合材料构件对高精度模具的广泛需求，综述了模具对复合材料构件成型精度的影响和作用机制，固化用模具材料及其设计与制造技术现状。重点详述了在制造精度、效率及成本综合考虑下，从模具材料到制造工艺的发展。最后，对当前大型复合材料构件高精度模具在材料、设计及制造技术方面的发展现状进行了总结，并对未来主要研究方向提出了明确建议。
- 复合材料航空件 /
- 热压罐固化 /
- 模具材料 /
- 模具设计 /
- 模具制造工艺
Abstract: Curing tooling is one of the key factors to induce the deformation of thermosetting resin matrix compo-site components. The development trend of integrated, mass, high precision and high performance of composite components for large aerospace composite material components has put forward higher requirements on the precision and life of curing tooling, and promoted the new development of tooling materials, design and manufacturing processing. However, there is still a lack of systematic review of relevant research. Therefore, contraposing the widespread demanding of high precision tooling for large aerospace composite material components, this paper summarizes the research status including interfacial functional mechanism between tooling and components, the pro-perties of tooling materials, the structural characteristics and manufacturing processing. The development from tooling material to manufacturing processing is emphasized in detail under the comprehensive consideration of manufacturing precision, efficiency and cost. Finally, the current development status of high precision tooling is summarized in aspect of materials, design and manufacturing technology for large composite components and the main research directions in the future are proposed.
- composites aeronautical components /
- autoclave curing process /
- tooling materials /
- tooling design /
- tooling manufacturing technology

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图 1 复合材料在民航客机和无人机上的用量

Figure 1. Usage of composite materials in civil aviation and UAV

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图 2 复合材料零件固化变形主要来源^[13]

Figure 2. Main sources of curing deformation for composite materials parts^[13]

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图 3 (a)固化过程中树脂结构演变过程^[19]；(b)模具界面剪切相互作用引起的变形演化过程^[20]

Figure 3. (a) Evolution of part deformation induced by tooling^[19];(b) Distortion due to shear interaction at tooling interface^[20]

σ—Normal stress; τ—Shear stress

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图 4 不同升温速率条件下模具-零件界面摩擦系数随固化度变化情况^[24]

Figure 4. Variation of interface friction coefficient between tooling and part with curing of degree under different heating rate^[24]

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图 5 不同模具-零件界面接触模型建立方法

Figure 5. Different method of establishing model of tooling-part interface

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图 6 四种接触建模方式诱导的翘曲变形对比^[25]

Figure 6. Comparison of warpage deformation induced by four contact modeling methods^[25]

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图 7 脱模剂和脱模布在不同情况下的力学作用效果比较^[43]

Figure 7. Comparison of mechanical effects of release agent and release film under different conditions^[43]

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图 8 铝、钢以及殷钢模具诱导固化变形情况对比^[51-52]

Figure 8. Comparison of curing deformation induced by aluminum, steel and invar tooling^[51-52]

Cross—Cross layer; Uni—Unidirectional layer; Quasi—Quasi-isotropic layer

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图 9 复合材料模具在典型航空回转体构件上的应用^[63]

Figure 9. Application of composite materials tooling at typical aeronautical parts^[63]

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图 10 两种典型模具预浸料材料形式

Figure 10. Two typical tooling prepreg material forms

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图 11 四种典型模具材料热膨胀系数（CTE）随温度变化情况^{[48-49, 54]}

Figure 11. Coefficient of thermal expansion (CTE) of four typical tooling materials varies with temperature^{[48-49, 54]}

Q235—Q235 steel; CFRP—Carbon fibre reinforced plastics

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图 12 典型材料组合式模具结构^[73-74]

Figure 12. Typical materials combined tooling structure^[73-74]

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图 13 金属和复合材料模具设计制造流程对比图

Figure 13. Comparison diagram of metal and composite tooling design and manufacturing

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图 14 不同模具形式在拐角处的制造缺陷^[86]

Figure 14. Manufacturing defects using different tooling forms at corners^[86]

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图 15 (a)框架式模具；(b)类回转体式模具^[92-93]

Figure 15. (a) Framed tooling; (b) Quasi-rotation tooling^[92-93]

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图 16 复合材料模具制造工艺^[95-96]

Figure 16. Manufacturing process of composite material toolings^[95-96]

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图 17 不同固化工艺比较^[104]

Figure 17. Comparison of different curing process ^[104]

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表 1 不同模具材料性能对比数据

Table 1. Comparison of performance data of different tooling materials

Materials	α/(10⁻⁶℃⁻¹)	T/℃	ρ/(g·cm⁻³)	E/GPa	Tr
Gypsum	–	<80	2.3	0.5-1	–
Chemical wood	30	<80	1.4	1.42	RAKU-TOOL®
Aluminium	24	<220	2.7	70	AA6082-T6
Steel	12	<220	7.85	210	–
Invar	1.1	>25	8.1	150	Invalite^TM
Carbon-epoxy	6.5	<160	1.57	60	M81 Hexcel Tool®
Carbon-BMI	3.8	<220	1.55	60	M61 Hexcel Tool®
Graphite	2.5	>25	1.3-2.0	8-15	–
C foam	4.5	>25	0.56	3.5	CFOAM^TM
Notes：α—Coefficient of thermal expansion of materials; T—Maximum using temperature; ρ—Material density; E—Tensile modulus(for anisotropic material is mean axis modulus); Tr—Typic trademark made of material; BMI—Bismalei-mide.

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表 2 阴模和阳模成型特点比较^[42]

Table 2. Comparison of molding characteristics between female and male mold

	Diagram	Applicable parts	Advantages	Disadvantages
Female mold		External work surface	● Regular shape ● High accuracy	● High cost ● Difficult layup ● Low production efficiency
Male mold		Inner work surface	● Tractable ● Easy layup ● High production efficiency	● Poor external surface quality ● Large spring-in angle

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