Numerical simulation of hot forming of aluminum-carbon fiber reinforced polypropylene hybrid hat-shaped rail
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摘要: 铝合金(Aluminum alloy，Al)-碳纤维增强聚丙烯(Carbon fiber reinforced polypropylene，CF/PP)混合材料通过热模压工艺可快速成形为车身薄壁构件，在汽车轻量化设计中应用前景广阔。然而，在热模压中Al主要以塑性变形为主，而CF/PP则以织物拉伸/剪切变形为主；此外，Al-CF/PP混合材料具有明显的热力耦合力学特性，为其数值模型的发展及热成形特性的研究带来了巨大挑战。本文首先通过热模压工艺制备8层(Al与CF/PP交替对称铺放)Al-CF/PP混合帽型梁试样，并采用X射线扫描断层(X-ray computed tomography，X-ray CT)手段对纤维夹角变化进行逐层表征。结果表明：Al-CF/PP中织物发生了明显的剪切变形；然后分别对Al片材和CF/PP片材在不同温度条件下开展单轴拉伸和偏轴拉伸实验，并构建了与温度相关的Al-CF/PP材料本构模型；在ABAQUS中构建了Al-CF/PP帽型梁的热模压有限元模型，仿真预测的纤维夹角变化与实验结果基本吻合；结果表明热模压过程中所有Al片材均出现了厚度减薄，CF/PP片材均经历了明显的剪切变形，Al-CF/PP层间材料则发生了显著的失效损伤。Abstract: Aluminum alloy (Al)-carbon fiber reinforced polypropylene (CF/PP) hybrid materials can be quickly formed into thin-walled components of the vehicle body by the hot press molding technology, and has broad application prospects in the lightweight design of automobiles. However, the Al mainly exhibits plastic deformation while the CF/PP mainly exhibits fabric tensile/shear deformations during the hot pressing process; In addition, the Al-CF/PP hybrid materials exhibit significant thermo-mechanical coupling characteristics, which bring huge challenges to numerical model developments and hot forming characteristic studies. The 8-layer (Al and CF/PP are alternately and symmetrically laid) Al-CF/PP hybrid hat-shaped rail specimen was prepared by the hot pressing technology, and the fiber angle variations were characterized through the X-ray computed tomography (X-ray CT) layer-by-layer, and the results indicate that the fabrics in Al-CF/PP undergo significant shear deformations; Then, the uniaxial and biaxial tensile experiments were conducted for Al sheets and CF/PP sheets under different temperature conditions, and the temperature-dependent material constitutive model of Al-CF/PP was constructed; And the hot press molding finite element model of the Al-CF/PP hat-shaped rail was developed in ABAQUS, and the predicted fiber angle variations by the simulation are basically consistent with the experimental results. The results indicate that all Al sheets occur thickness reductions, all CF/PP sheets undergo obvious shear deformations and interlayer materials between Al and CF/PP occur significant failure damages during the hot press molding process.
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Key words:
- Al-CF/PP rail /
- hot press molding /
- formability /
- constitutive model /
- numerical simulation
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图 1 Al和碳纤维增强聚丙烯(CF/PP)片材的单轴拉伸和偏轴拉伸测试
DIC—Digital image correlation
Figure 1. Uniaxial and bias-extension tests for Al and carbon fiber reinforced polypropylene (CF/PP) sheets
图 2 Al片材在不同温度条件下的拉伸应力-应变曲线
Figure 2. Tensile stress-strain curves of Al sheets under different temperature conditions
图 3 CF/PP预浸料在不同温度下的应力-剪切角曲线
Figure 3. Bias-extension stress-shear angle curves of CF/PP prepreg under different temperature conditions
图 4 Al-CF/PP混合帽型梁的制备工艺示意图及CT扫描流程图
R—Radius
Figure 4. Schematic diagram of manufacturing process and CT scanning flowchart of Al-CF/PP hybrid hat-shaped rail
图 5 第4层CF/PP的CT图像及其9个点的纤维角度
Figure 5. CT images of the 4th CF/PP and the fiber angles of nine points
图 6 第5层CF/PP的CT切片图像及其9个点的纤维角度
Figure 6. CT images of the 5th CF/PP and the fiber angles of nine points
图 7 纤维剪切变形示意图
Figure 7. Schematic diagram of the fiber yarn shear deformation
$ {\theta _1} $, $ {\theta _2} $—Shear angles of the weft yarn and warp yarns, respectively; $ \alpha $—Shear angle between the weft and warp yarns; $({\underline e _1},{\underline e _2}) $ is the current local orthogonal coordinate system; $({ }^1 \underline{\boldsymbol{f}}_\alpha, { }^2 \underline{\boldsymbol{f}}_\alpha , \alpha=1,2$) is the current fiber coordinate system; $(\underline e _1^0,\underline e _2^0) $ is the initial local orthogonal coordinate system; $(\underline{\boldsymbol{f}}_1^0, \underline{\boldsymbol{f}}_2^0) $ is the initial fiber coordinate system
图 9 实验与仿真之间的Al-CF/PP混合梁成形轮廓对比
Figure 9. Comparisons in forming profiles of the Al-CF/PP hybrid rail between experiment and simulation
图 10 实验与仿真之间关于第4层中不同点处的纤维角度变化对比
Figure 10. Comparisons in fiber angle variations in different points of the 4th layer between experiment and simulation
图 11 实验与仿真之间关于第5层中不同点处的纤维角度变化对比
Figure 11. Comparisons in fiber angle variations in different points of the 5th layer between experiment and simulation
图 12 Al片材的厚度减薄对比
STH—Section thickness
Figure 12. Comparisons in thickness thinning of Al sheets
图 14 Al-CF/PP帽型梁内部片材的界面失效对比
Figure 14. Comparisons in interface failure of inner sheets of the Al-CF/PP hybrid rail
表 1 铝合金片材的主要化学成分 (wt%)
Table 1. Major chemical composition of the alloy sheet (wt%)
Element Si Fe Cu Mn Mg Cr Zn Value 0.59 0.12 0.24 0.11 1.02 0.24 0.07 
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表 2 Al片材的Johnson-Cook (JC)模型材料参数
Table 2. Johnson-Cook (JC) model material properties of the Al sheet
Parameter A B n Tmelt /K Value 126.23 22.42 0.054 923.15 Notes: A, B, n are undetermined parameters in JC model, which can be calibrated at reference temperature and reference rate; Tmelt—Melting temperature.
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表 3 CF/PP预浸料的次弹性模型参数
Table 3. Hypoelastic model parameters of the CF/PP prepreg
Parameter $ {a_1} $ $ {a_2} $ $ {a_3} $ $ {a_4} $ $ {a_5} $ A Value 2.08 −4.93 5.45 −2.88 0.97 −2.16 Note: a1, a2, a3, a4 and a5 are fitting parameters for shear stiffness C33.
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表 4 Al片材与CF/PP片材界面材料的粘胶参数
Table 4. Cohesive parameters of the interface material between Al sheets and CF/PP sheets
Cohesive $ {K_{{\text{nn}}}} $/(GPa·m−1) $ {K_{{\text{ss}}}} $/(GPa·m−1) $ {K_{{\text{tt}}}} $/(GPa·m−1) $ \delta _{\text{n}}^{\text{0}} $/MPa $ \delta _{\text{s}}^{\text{0}} $/MPa $ \delta _{\text{t}}^{\text{0}} $/MPa $ \delta _{\text{m}}^{{\text{max}}} $/mm Value 8.0 8.0 8.0 0.001 0.001 0.001 0.001 Notes: $ {K_{{\text{nn}}}} $,$ {K_{{\text{ss}}}} $,$ {K_{{\text{tt}}}} $—Normal and shear stiffness parameters, respectively; $ \delta _{\text{n}}^{\text{0}} $, $ \delta _{\text{s}}^{\text{0}} $and $ \delta _{\text{t}}^{\text{0}} $—Normal and shear strength parameters, respectively; $ \delta _{\text{m}}^{{\text{max}}} $—Effective separation at damage initiation.
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表 5 CT测试和FEA预测中第4层和第5层中不同点处的纤维角变化对比
Table 5. Comparisons in fiber angle variations in different points of 4th and 5th layers between CT test and FEA prediction
Layer CT Shear angle/(°) FEA Shear angle/(°) |Error|/% Ply-4
(CF/PP)A 98.5 a 95.8 2.74 D 99.5 d 97.5 2.01 G 99.5 g 98.8 0.70 E 99.0 e 95.1 3.94 F 100.0 f 115.3 15.30 I 97.0 i 111.4 14.80 Ply-5
(CF/PP)A' 99.0 a' 97.4 1.61 D' 100.5 d' 98.8 1.69 G' 99.0 g' 96.4 2.63 E' 100.0 e' 97.8 2.20 F' 99.0 f' 98.4 0.60 I' 99.0 i' 98.0 1.01
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