超厚壁变曲率复合材料扩张段固化过程力-热耦合分析

梁群; 冯喜平; 张坤; 闫航; 李建; 侯晓

doi:10.13801/j.cnki.fhclxb.20220621.002

超厚壁变曲率复合材料扩张段固化过程力-热耦合分析

doi: 10.13801/j.cnki.fhclxb.20220621.002

梁群^1,,
冯喜平^1,,
张坤¹,
闫航¹,
李建²,
侯晓^1, ,

1.
西北工业大学　航天学院，西安 710072
2.
西安航天复合材料研究所，西安 710025

基金项目: 国家自然科学基金(U1837601)

详细信息

通讯作者:
侯晓，中国工程院院士，博士，研究员，博士生导师，研究方向为固体火箭发动机先进材料与结构技术　E-mail: houxiao@nwpu.edu.cn

中图分类号: TB330.1
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- 被引次数: 0
出版历程
- 收稿日期: 2022-05-24
- 修回日期: 2022-06-14
- 录用日期: 2022-06-20
- 网络出版日期: 2022-06-22
- 刊出日期: 2022-08-22

Mechanical-thermal coupling analysis of curing process of composite divergent section with ultra-thick and variable curvature

LIANG Qun^1
,,
FENG Xiping^1
,,
ZHANG Kun¹,
YAN Hang¹,
LI Jian²,
HOU Xiao^{1
, ,}

1.
School of Astronautics, Northwestern Polytechnical University, Xi’an 710072, China
2.
Xi'an Aerospace Composite Research Institute, Xi’an 710025, China

摘要

摘要: 复合材料扩张段是固体发动机喷管的关键部件，为抵抗高温、高压、烧蚀、高速燃气和力学载荷的综合作用，其结构为超厚壁变曲率的复杂混合复合材料结构。由于扩张段的低导热性、超厚壁特征和固化工艺的不合理，成型过程容易出现剧烈的过热峰。为减小固化变形，提高扩张段成型质量，必须抑制固化过热，提高固化均匀性。本文首先采用高压差示扫描量热仪表征2 MPa压力下高硅氧玻璃纤维/酚醛和碳纤维/酚醛预浸料的动力学。然后考虑成型过程多场耦合特点及成型模具和固化工艺的影响，构建固化过程耦合模型，分析扩张段固化过热和非均匀固化现象。最后，提出在剧烈固化前插入降温段的方法优化固化工艺，抑制固化过热。结果表明，优化工艺可以有效抑制扩张段过热现象，优化后最大过热峰由54.2℃下降为23.5℃，最大固化度差值由0.6下降为0.34，下降幅度分别为56.64%和43.33%。
- 扩张段 /
- 变曲率 /
- 超厚壁复合材料 /
- 过热 /
- 非同步固化
Abstract: Composite divergent section is the key component of solid rocket motor nozzle, with the composite structure of ultra-thick and variable curvature to resist the comprehensive effects of high temperature, ablation, high-speed gas and mechanical load. Due to the low thermal conductivity of the divergent section, the characteristics of ultra-thick and the unreasonable curing cycle, severe overheating peaks are easy to appear during the molding process. In order to reduce the curing deformation and improve the forming quality of the divergent section, it is necessary to restrain the curing overheating and improve the curing uniformity. Firstly, the kinetics of high silica glass fiber/phenolic and carbon fiber/phenolic prepreg at 2 MPa were characterized by high pressure differential scanning calorimetry in this study. Then, considering the characteristics of multi field coupling in the molding process and the influence of molding die and curing process, the coupling model of curing process was constructed to analyze the phenomenon of overheating and non-uniform curing of the divergent section. Finally, the method of inserting a cooling process before vigorous curing was proposed to optimize the curing cycle and restrain the curing overheating. The results show that the optimized cycle can effectively suppress the overheating of the divergent section. After optimization, the maximum overheating peak decreases from 54.2℃ to 23.5℃, and the maximum curing degree difference decreases from 0.6 to 0.34, with the decrease ranges of 56.64% and 43.33% respectively.
- divergent section /
- variable curvature /
- ultra-thick composites /
- overheat /
- asynchronous curing

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图 2 扩张段的制造过程^[30]

Figure 2. Manufacturing process of divergent section^[30]

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图 3 DSC放热曲线：(a) 高硅氧玻璃纤维/酚醛(GF-HSi/PF)预浸料；(b) 碳纤维/酚醛(CF/PF)预浸料

Figure 3. DSC exothermic curves: (a) High silica glass fiber/phenolic (GF-HSi/PF) prepreg; (b) Carbon fiber/phenolic (CF/PF) prepreg

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图 1 复合材料扩张段结构示意图

Figure 1. Structural diagram of composite divergent section

CF/PF—Carbon fiber/phenolic; GF-HSi/PF—High silica glass fiber/phenolic

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图 4 扩张段成型过程结构示意图

Figure 4. Structural diagram of divergent section during manufacturing process

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图 5 扩张段结构网格划分与网格质量示意图

Figure 5. Schematic diagram of grid and grid quality of divergent section

Γ—Boundary

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图 6 原固化工艺

Figure 6. Conventional curing cycle

T₁, T₂ and T₃—Temperature of the first dwelling process, the second dwelling process and the end temperature of the first cooling process, respectively; t₁, t₂, t₃, t₄ and t₅—Start time of the first dwelling process, the end time of the first dwelling process, the start time of the second dwelling process, the end time of the second dwelling process and the end time of the first cooling process, respectively

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图 7 扩张段温度云图：(a) t=200 min(固化早期)；(b) t=290 min(剧烈反应时刻)；(c) t=420 min(固化基本结束)

Figure 7. Temperature nephogram diagrams of divergent section: (a) t=200 min (Early curing); (b) t=290 min (Violent curing); (c) t=420 min (Curing basically ends)

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图 8 反应剧烈时扩张段固化度云图

Figure 8. Nephogram diagram of curing degree for divergent section under violent curing

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图 9 扩张段特征点：(a) 结构小端；(b) 结构大端

Figure 9. Characteristic points of divergent section: (a) Small end of structure; (b) Big end of structure

Point 1, 2 and 3—Center point of CF/PF composite layer, the interface point of two layers and the center point of GF-HSi/PF composite layer at the small end of divergent section, respectively; Point 4, 5 and 6—Center point of CF/PF composite layer, the interface point of two layers and the center point of GF-HSi/PF composite layer at the large end of divergent section, respectively.

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图 10 扩张段结构特征点计算结果：(a) 温度曲线；(b) 过热峰与固化速率关系

Figure 10. Calculation results of characteristic points for divergent section: (a) Temperature curves; (b) Relationship between overheating peak and curing rate

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图 11 不同扩张段的固化度-时间曲线

Figure 11. Curing degree-time curves for different divergent section

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图 12 扩张段优化的固化工艺

Figure 12. Optimized curing cycle of divergent section

T₄—End temperature of the first cooling process; t₃, t₄, t₅, t₆, t₇, t₈ and t₉—Start time of the inserted cooling process, the end time of the inserted cooling process, the start time of the second dwelling process, the end time of the second dwelling process, the start time of the third dwelling process, the end time of the third dwelling process and the end time of the first cooling process, respectively

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图 13 扩张段优化工艺后温度和固化度云图：(a) t=340 min扩张段温度；(b) t=340 min扩张段固化度

Figure 13. Nephogram diagram of temperature and curing degree after optimizing the process for divergent section: (a) Temperature nephogram at t=340 min; (b) Curing degree nephogram at t=340 min

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图 14 扩张段优化后特征点温度和固化度曲线：(a) 温度曲线；(b) 过热峰与固化速率关系

Figure 14. Calculation results of characteristic points under optimized cure cycle for divergent section: (a) Temperature curves; (b) Relationship between overheating peak and curing rate

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表 1 峰值温度和反应总放热量

Table 1. Peak temperature and total reaction heat release

Material	β/(℃·min⁻¹)	T_p/℃	$ \Delta H $/(J·g⁻¹)	$ \Delta \bar H $/(J·g⁻¹)
GF-HSi/PF	5	155.68	114.68	103.20
	10	169.80	118.94
	15	178.35	101.36
	20	183.87	77.81
CF/PF	5	147.50	100.96	117.44
	10	162.14	116.06
	15	169.91	136.77
	20	175.50	115.98
Notes: β—Heating rate; T_p—Peak temperature; ΔH—Total reaction heat under different heating rate; $ \Delta \bar H $—Average total reaction heat.

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表 2 GF-HSi/PF预浸料固化反应动力学参数

Table 2. Cure kinetics parameters of GF-HSi/PF prepreg

β/ (℃·min⁻¹)	Stage I (0<α<0.69)			Stage II (α≥0.69)
β/ (℃·min⁻¹)	A×10⁻⁵ / (1·s⁻¹)	m	n	A×10⁻⁵ / (1·s⁻¹)	n
5	39.809	0.1982	0.9357	29.762	0.7410
10	39.458	0.1760	0.8034	30.894	0.6455
15	40.360	0.1896	0.7253	32.122	0.5885
20	42.621	0.2406	0.6837	33.631	0.5524
Average	40.562	0.2011	0.7870	31.602	0.6319
Notes: α—Curing degree; A, m, n—Dynamic parameters.

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表 3 CF/PF预浸料固化反应动力学参数

Table 3. Cure kinetics parameters of CF/PF prepreg

β/ (℃·min⁻¹)	Stage I (0<α<0.36)			Stage II (α≥0.36)
β/ (℃·min⁻¹)	A×10⁻⁵/ (1·s⁻¹)	m	n	A×10⁻⁵/ (1·s⁻¹)	n
5	37.153	0.3456	1.5324	20.364	0.9521
10	32.461	0.2808	1.3302	19.390	0.8029
15	29.317	0.3181	1.2746	17.120	0.7801
20	28.132	0.2296	1.0466	20.151	0.7628
Average	31.766	0.2935	1.2960	19.256	0.8245

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表 4 扩张段结构材料参数

Table 4. Thermal parameters of divergent section

	ρ/ (kg·m^–3)	k/(W·(m·K)^–1)	C_p/ (J·(kg·K)^–1)	V_f/vol%
CF/PF	1715	{0.6, 3, 3}	Table 5	56.0
GF-HSi/PF	1470	{0.45,0.55, 0.55}	Table 5	66.5
Steel	7850	46	502.4	–
Rubber	1120	0.28	1494	–
Notes: ρ—Density; k—Thermal conductivity; C_p—Specific heat; V_f—Volume fraction of fiber.

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表 5 复合材料比热容

Table 5. Specific heat capacity of composites

Temperature/℃	CF/PF	GF-HSi/PF
25	950.0	950.0
50	1052.5	1094.9
100	1338.8	1485.2
150	1362.5	1517.6

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