基于加工变形的复合材料固化残余应力评估方法

刘学术; 乔仁勇

基于加工变形的复合材料固化残余应力评估方法

刘学术^,,
乔仁勇

大连理工大学　汽车工程学院, 大连 116000

基金项目: 中央高校基础科研业务费(DUT21 GF305)；山东省海上航天装备技术创新中心(鲁东大学)开放课题基金(MAETIC2021-04)

详细信息

通讯作者:
刘学术，博士，副教授，硕士生导师，研究方向为复合材料制件连接装配　E-mail:liuxs@dlut.edu.cn

中图分类号: TB332
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- HTML全文浏览量: 179
- PDF下载量: 5
- 被引次数: 0
出版历程
- 收稿日期: 2022-07-29
- 修回日期: 2022-09-02
- 录用日期: 2022-09-15
- 网络出版日期: 2022-09-27
- 刊出日期: 2023-07-15

Cure-induced residual stresses assessment of composite materials based on machining deformation

LIU Xueshu^,,
QIAO Renyong

School of Automotive Engineering, Dalian University of Technology, Dalian 116000, China

Funds: The Fundamental Research Funds for the Central Universities (DUT21 GF305); Supported by the Open Project Program of Shandong Marine Aerospace Equipment Technological Innovation Center, Ludong University (Grant No. MAETIC2021-04)

摘要

摘要: 各向异性的复合材料在固化成型过程中极易产生残余应力，直接影响后续的加工与连接装配。因此，掌握复合材料固化残余应力的分布规律是实现复合材料制件高性能制造的前提和基础。本文在分析传统切割槽法测量应力的基础上，根据变形产生机制将制件在切割槽加工后所产生的变形分为由固化残余应力释放及重力引起的两部分组成。在利用有限元方法给出重力影响制件几何变形规律后，依据弯曲变形理论建立了固化残余应力与试件几何变形之间的映射关系，并据此获得固化残余应力分布状态。与传统切割槽法所得结果对比后表明：本文所提方法能得到与传统切割槽法相一致的应力分布规律；当选择合适的测量点位置后二者对固化残余应力估算的平均误差可控制在14%以内。
- 复合材料 /
- 固化 /
- 残余应力 /
- 测量 /
- 切割槽法
Abstract: Cure-induced residual stresses are usually unavoidable due to anisotropic properties of composite materials, which have great influence on following machining and assembly process. Therefore, it is necessary to understand the distribution of cure-induced residual stresses in the materials for high performance composite part manufacturing. The traditional slitting method used for residual stresses assessment was analyzed and deformations caused by the slitting process were divided into two groups. One was caused by the release of cure-induced residual stresses and the other was by gravity. After the partial deformation caused by gravity being obtained by using finite element analysis, relationship between the remained deformation and the cure-induced residual stresses was set up by using bending deformation theory, which was used to evaluate the distribution of cure-induced residual stresses. Experimental results show that the proposed method can obtain the same distribution as that of the traditional slitting method and the difference may less than 14% when a proper measurement point is selected.
- composites /
- cure /
- residual stress /
- measurement /
- slitting method

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图 1 切割槽法示意图

Figure 1. Slitting method schematic

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图 2 变形区域简化力学模型

Figure 2. Mechanical model of deformation region

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图 3 力学模型

Figure 3. Mechanical model

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图 4 三角附加应力

Figure 4. Triangular additional stress

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图 5 激光测距仪固定位置及试验装置图

Figure 5. Laser rangefinder location and experimental setup

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图 6 激光测距仪及应变片布置示意图

Figure 6. Schematic diagram of laser rangefinder and strain gauge arrangement

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图 7 有限元模型

Figure 7. Finite element model

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图 8 铝合金-复合材料层压板不同位置处应变-切深关系曲线

Figure 8. Strain-depth curves of aluminum-composite laminate at different locations

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图 9 铝合金-复合材料层压板不同位置处应力-切深曲线

Figure 9. Stress-depth curves of aluminum-composite laminate at different locations

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图 10 铝合金-复合材料层压板不同位置处位移-切深曲线

Figure 10. Displacement-depth curves of aluminum-composite laminate at different locations

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图 11 铝合金-复合材料层压板重力产生位移-切深曲线

Figure 11. Displacement-depth curves induced by gravity of aluminum-composite laminate

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图 12 重力消除后铝合金-复合材料层压板位移-切深曲线

Figure 12. Displacement-depth curves of aluminum-composite laminate without gravity

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图 13 铝合金-复合材料层压板半解析法与切割槽法应力对比曲线

Figure 13. Stress comparison curves of aluminum-composite laminate between the semi-analytical method and the slitting method

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表 1 试件力学性能

Table 1. Mechanical properties of specimen

Aluminum	E=70 GPa	G=27 GPa	ν=0.33
Composite	E_x=E_y=6.5 GPa	G_xy=2.5 GPa	ν=0.31

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表 2 加工参数

Table 2. Machining parameters

Spindle speed/(r·min⁻¹)	Feed rate /(mm·min⁻¹)	Cutting depth/mm	Cutting times
4000	180	1	29

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表 3 铝合金-复合材料层压板应力对比及误差分析

Table 3. Stress comparison and error analysis of aluminum-composite laminate

Depth/mm	Slitting method/MPa	Semi-analytical method/MPa			Error/%
Depth/mm	Slitting method/MPa	80	100	140	80	100	140
1	0.71	0.49	0.46	0.46	30.8	34.9	35.3
2	−0.19	−0.11	−0.07	−0.05	43.4	60.7	72.0
3	−1.03	−0.67	−0.67	−0.62	35.2	35.0	39.9
4	−1.55	−1.14	−1.16	−1.16	26.2	25.0	24.8
5	−1.85	−1.51	−1.55	−1.59	18.5	16.3	13.9
6	−1.97	−1.80	−1.72	−1.83	8.7	12.6	7.2
7	−1.92	−1.83	−1.92	−1.92	4.9	0.0	0.3
8	−1.74	−1.64	−1.63	−1.77	5.7	6.3	1.9
9	−1.44	−1.42	−1.49	−1.55	0.9	3.5	7.6
10	−1.04	−1.15	−1.11	−1.09	10.7	7.1	4.9
11	−0.57	−0.68	−0.64	−0.55	19.1	12.8	3.3
12	−0.05	−0.12	−0.03	−0.06	124.0	51.1	21.8
13	0.49	0.50	0.55	0.38	2.1	11.4	23.2
14	1.04	1.11	1.20	1.05	6.9	15.7	1.3
15	1.57	1.89	1.84	1.80	20.3	17.7	14.7
16	2.05	2.48	2.36	2.31	20.9	15.0	12.3
17	2.48	2.97	2.94	2.83	19.8	18.8	14.1
18	2.81	3.35	3.34	3.20	19.0	18.6	14.0
19	3.04	3.56	3.49	3.44	17.3	14.7	13.1
20	3.13	3.59	3.49	3.48	14.6	11.5	11.3
21	3.07	3.30	3.28	3.24	7.7	6.9	5.7
22	2.83	2.81	2.79	2.80	0.5	1.2	0.8
23	2.38	2.21	2.22	2.28	7.4	6.7	4.2
24	1.72	1.54	1.63	1.64	10.5	5.2	4.6
25	0.80	0.58	0.69	0.79	28.2	13.7	1.8
26	−0.38	−0.33	−0.30	−0.34	12.3	19.4	9.4
27	−1.85	−1.46	−1.47	−1.57	21.0	20.5	15.2
28	−3.24	−2.50	−2.63	−2.75	22.9	18.7	15.2
29	−4.57	−3.61	−3.73	−3.92	20.9	18.3	14.3
	Average error				20.0	17.2	14.1

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