A simulation method of forming wrinkle defects in thermoplastic woven fabric prepregs in a wide temperature range based on non-orthogonal constitutive model
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摘要: 热塑性复合材料预制体的赋形质量直接影响结构件的制造质量。由于热塑性基体具有较高的熔融温度和黏度，赋形工艺温度设计不合理会导致褶皱等赋形缺陷，给热塑性复合材料结构高质量成型带来了挑战。现有的热塑性预浸料热成型研究主要基于连续介质力学、离散元、半离散元法，通过建立多机制耦合的本构模型分析热塑性预浸料的各向异性大变形行为，未充分考虑工艺调控对赋形宏观变形过程中褶皱缺陷的影响。发展了一种热塑性预浸料宽温域赋形褶皱缺陷仿真方法。通过表征热塑性机织物预浸料在不同温度、载荷下的力学性能，获取宽温域热塑性预浸料本构参数，基于非正交本构模型，提出了温度对热塑性预浸料赋形褶皱缺陷的作用规律，揭示了赋形过程中宽温域褶皱缺陷的变形机制，获得了赋形温度优化调控方案。研究结果表明：褶皱缺陷的萌生和演化过程由不同温度下的面内剪切和压缩变形行为共同影响，预浸料的褶皱缺陷变形程度随温度的增加而减弱，非正交本构模型的模拟结果与实验结果基本一致。Abstract: The forming quality of thermoplastic composite preforms directly affects the manufacturing quality of structure. Due to the high melting temperature and viscosity of thermoplastic matrix, unreasonable design of forming process temperature will lead to forming defects such as wrinkles, which brings challenges to high-quality forming of thermoplastic composite structures. Currently, the existing researches on thermoforming of thermoplastic prepregs are mainly based on the continuous, the discrete and the semi-discrete approaches, the anisotropic large deformation behavior of thermoplastic prepreg is analyzed by establishing a multi-mechanism coupled constitutive model, which is not fully considered the influence of process control on wrinkle defects during forming macroscopic deformation. In this paper, a simulation method of forming wrinkle defects in thermoplastic prepregs in a wide temperature range was developed. By characterizing the mechanical properties of thermoplastic woven fabric prepregs at different temperatures and loads, the non-orthogonal constitutive model parameters of thermoplastic prepregs in a wide temperature range were obtained. The effect of temperature on forming wrinkle defects in thermoplastic prepregs was proposed, and the deformation mechanism of wrinkle defects in a wide temperature range in the forming process was revealed, and the optimal control scheme of forming temperature was obtained. The research results show that the initiation and evolution of wrinkle defects has been affected by the in-plane shear and compressive deformation behaviors at different temperatures, the deformation degree of wrinkle defects of prepreg has been decreased with the increase of temperature. The simulation results of the non-orthogonal constitutive model are basically closer to the experimental results.
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图 2 (a) 单轴拉伸实验；(b) 偏轴拉伸实验
Figure 2. (a) Uniaxial tension experiment; (b) Bias-extension experiment
图 4 各温度下CF/PC预浸料的单轴拉伸实验应力-应变曲线
Figure 4. Stress-strain curves of uniaxial tension experiments of CF/PC prepreg at different temperatures
图 5 各温度下CF/PC预浸料偏轴拉伸实验纤维剪切角变化
Figure 5. Variation of fiber shear angle in bias-extension experiments of CF/PC prepreg at different temperatures
图 6 升温过程中CF/PC的预浸料弯曲变形图：(a) 25℃；(b) 150℃；(c) 250℃
Figure 6. Bending deformation diagram of CF/PC prepreg during heating process: (a) 25℃; (b) 150℃; (c) 250℃
图 7 各温度下CF/PC预浸料悬臂梁弯曲实验结果
Figure 7. Bending experiment results of cantilever beam for CF/PC prepreg at different temperatures
图 8 非正交本构模型不同坐标系定义
Figure 8. Definition of different coordinate systems for non-orthogonal models
$f_1^0$, $f_2^0$—Prepreg initial yarn orientation; $e_1^0$, $e_2^0$—Initial local corotation coordinate system orientation; e1, e2—Direction of the local co-rotating coordinate system after deformation; f1, f2—Prepreg yarn orientation after deformation; α—Angle between f1 and e1; β—Shear angle; m1—Bisector of e1 and e2
图 9 单层CF/PC预浸料的单穹顶结构赋形模型示意图
Figure 9. Schematic diagram of the preforming model of the single dome structure of CF/PC monolayer prepreg
图 10 (a) CF/PC赋形试件；(b) 单穹顶实验装置
Figure 10. (a) CF/PC shaped specimen; (b) Single-dome experimental device
图 11 CF/PC预浸料各温度下褶皱缺陷仿真与实验对比
Figure 11. Comparison of wrinkle defect in simulation and experiment results of CF/PC prepreg at each temperature
表 1 平纹碳纤维/聚碳酸酯(CF/PC)机织物预浸料参数
Table 1. Parameters of plain weave carbon fiber/polycarbonate (CF/PC) woven fabric prepreg
Parameter Fabric Weave Plain Density/(kg·mm−3) 1.461×10−6 Thickness/mm 0.35 Fiber volume fraction/vol% 45 Glass transition temperature Tg/℃ 150 Melting point Tm/℃ 220 Fabric image 
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表 2 纤维剪切角变化拟合曲线
Table 2. Fitting curve of fiber shear angle change
Temperature/℃ Curve fitting parameter Coefficient of determination R2 200 $y=-74.21 x^6+216.57 x^5-275.98 x^4+184.66 x^3-60.72 x^2+10.92 x$ 0.99996 210 $y=-7.86 x^6+48.83 x^5-99.01 x^4+85.52 x^3-32.09 x^2+6.84 x$ 0.99998 220 $y=106.35 x^6-252.89 x^5+208.95 x^4-66.94 x^3+4.25 x^2+2.92 x$ 0.99998 230 $y=74.43 x^6-185.49 x^5+162.48 x^4-57.72 x^3+6.17 x^2+1.83 x$ 0.99997 240 $y=76.99 x^6-189.97 x^5+169.8 x^4-66.76 x^3+10.68 x^2+0.97 x $ 0.99999 250 $y=66.99 x^6-168.78 x^5+155.42 x^4-64.17 x^3+11.36 x^2+0.64 x $ 0.99998
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表 3 CF/PC预浸料拉深距离仿真与实验对比
Table 3. Comparison of draw-in values from experiment and simulation of CF/PC prepreg
Temperature/℃ X direction/mm Y direction/mm Experiment Simulation Experiment Simulation 200 28.7 28.6 28.8 28.4 210 29.4 29.3 29.5 29.5 220 29.6 29.7 29.6 29.2 230 29.5 29.5 29.7 29.6 240 29.7 29.7 29.8 29.7 250 29.8 29.9 29.9 29.6
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表 4 纤维剪切角仿真与实验对比(210℃)
Table 4. Comparison of fiber shear angle values from experiment and simulation (210℃)
Position Shear angle/(°) Error/% Experiment Simulation 1 89.8 89.9 0.11 2 79.3 78.5 1.00 3 68.4 65.6 4.10 4 48.7 46.9 3.70 5 89.8 89.9 0.11 6 89.5 89.6 0.12 7 86.3 86.1 0.23
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