Mold filling process and simulation of sandwich composites with damping layer
-
摘要: 在复合材料中引入黏弹性阻尼层是改善复合材料结构振动特性的有效方法。针对穿孔硅橡胶夹芯复合材料的真空辅助树脂传递工艺(VARTM)进行了实验与仿真分析。首先采用恒压注射条件分别测试了纤维增强材料及加入导流网后的等效渗透率。然后搭建了实验室VARTM观测平台进行了充模实验,同时基于RTM-Worx软件建立了树脂充模模型。通过对比实验与仿真的树脂流动状态图及不同时刻的填充面积,验证了仿真模型的有效性。最后,探究了阻尼层穿孔列间距、行距、直径及“边缘效应”等参数对树脂充模的时间及充模过程的影响。结果表明:仿真模型能够较好预测树脂流动情况,不合理的阻尼层参数会影响树脂的流动甚至导致缺陷的产生。
-
关键词:
- 真空辅助树脂传递模塑 /
- 夹芯复合材料 /
- 充模过程 /
- 渗透率 /
- 边缘效应
Abstract: Introducing viscoelastic damping layer into composites is an effective method to improve the composite structural vibration characteristics. The vacuum assisted resin transfer molding (VARTM) process of sandwich composites with perforated silicone rubber was investigated by experiment and simulation. Firstly, the equivalent permeability of fiber reinforced materials and its combination with the flow medium were tested under constant pressure injection conditions. Then, the VARTM platform was set up to observe mold filling experiment in the laboratory. The resin filling model was established based on the RTM-Worx software. The validity of the simulation model was verified by comparing the experimental resin flow diagram and the filling area with simulated results at different time. Finally, the effects of the parameters such as the spacing between columns, the row spacing, the diameter of the holes in the damping layer and the "edge effect" on the resin filling time and the filling process were discussed. The results show that the simulation model can better predict the resin flow behavior, and unreasonable parameters of damping layer can affect the resin flow and even lead to defects. -
表 1 材料参数测试结果
Table 1. Test results of material parameters
Laminate
typeEquivalent
porosity/%Average permeability/
(10−11 m2)Length wise Kx Width wise Ky EW200 57.4 2.78 2.67 EW200+ 60.0 115 83 表 2 阻尼层穿孔间距对含阻尼层夹芯复合材料VARTM成型树脂流动的影响
Table 2. Effects of damping layer perforation spacing on resin flow in VARTM sandwich composites with damping layer
Process parameter Resin flow diagram at 50% filling modulus of the preform D=2 mm, C=15 mm
Change row space SD=2 mm, S=15 mm
Change column space C表 3 不同穿孔直径对应的含阻尼层夹芯复合材料VARTM成型孔洞渗透率
Table 3. Permeability of VARTM sandwich composites with damping layer in different perforation diameters
Diameter/mm Porosity/mm2 0.5 3.927×10−5 1 0.0127 2 0.161 3 0.498 4 1.031 5 1.758 6 2.682 7 3.802 8 5.118 -
[1] SUN S, WANG X, LIANG J, et al. Analysis on fracture behaviour of stitched foam sandwich composites using interlaminar tension test[J]. Journal of Sandwich Structures & Materials,2022,24(3):1515-1534. [2] SERRANO-GONZÁLEZ J, LACAL-ARÁNTEGUI R. Technological evolution of onshore wind turbines-A market-based analysis[J]. Wind Energy,2016,19(12):2171-2187. doi: 10.1002/we.1974 [3] ZHOU X Q, YU D Y, SHAO X Y, et al. Research and applications of viscoelastic vibration damping materials: A review[J]. Composite Structures,2016,136:460-480. doi: 10.1016/j.compstruct.2015.10.014 [4] LAKES R S. High damping composite materials: Effect of structural hierarchy[J]. Journal of Composite Materials,2002,36(3):287-297. doi: 10.1177/0021998302036003538 [5] 邓京兰, 王继辉, 连军. RTM充模过程(Ⅱ): 有限元分析[J]. 武汉理工大学学报, 2003, 25(8): 48-51.DENG Jinglan, WANG Jihui, LIAN Jun. Computer simulation of RTM mold filling processes(II): FEM analysis[J]. Journal of Wuhan University of Technology, 2003, 25(8): 48-51(in Chinese). [6] YOON M K, DOLAN D F. Homogenous modeling of VARTM processes with hybrid layered media[J]. Journal of Composite Materials,2008,42(8):805-824. doi: 10.1177/0021998307088567 [7] YANG B, JIN T, BI F, et al. Modeling the resin flow and numerical simulation of the filling stage for vacuum-assisted resin infusion process[J]. Journal of Reinforced Plastics and Composites,2014,33(21):1976-1992. doi: 10.1177/0731684414551039 [8] SHEVTSOVA S, ZHILYAEVB I, CHANG S H, et al. Two-stage numerical approach for reliable recognition of dry spots at the VAP infusion of large composite parts of complex shape[J]. Composites Structures,2021,259:113437. doi: 10.1016/j.compstruct.2020.113437 [9] 赖家美, 王德盼, 陈显明, 等. VARTM工艺中高渗透导流介质对树脂充填行为的影响[J]. 高分子材料科学与工程, 2014, 30(7):120-125, 131. doi: 10.16865/j.cnki.1000-7555.2014.07.025LAI Jiamei, WANG Depan, CHEN Xianming, et al. Effects of high-permeability medium on resin filing behavior in vacuum assisted resin transfer molding process[J]. Polymeric Materials Science and Engineering,2014,30(7):120-125, 131(in Chinese). doi: 10.16865/j.cnki.1000-7555.2014.07.025 [10] 李彩林, 高霞, 柳鑫, 等. VARI液体成型复合材料机盖的数值模拟及工艺验证[J]. 塑料工业, 2020, 48(2): 92-96, 174.LI Cailin, GAO Xia, LIU Xin, et al. Digital simulation and progress verification of composite cover plate by VARI technology[J]. Plastics Industry, 2020, 48(2) : 92-96, 174(in Chinese). [11] 叶乔丹, 吴晓青. 真空灌注成型工艺导流网和夹层结构沟槽设计的模拟研究[J]. 纤维复合材料, 2018, 35(1): 25-32.YE Qiaodan, WU Xiaoqing. Study of flow medium and groove design of sandwich structure VARTM process molding[J]. Fiber Composites, 2018, 35(1): 25-32(in Chinese). [12] GRAY W G, MILLER C T. Examination of darcy's law for flow in porous media with variable porosity[J]. Environmental Science & Technology,2004,38:5895-5901. [13] 詹东, 杨睿, 孙士勇. RTM成型工艺中纤维体积密度不均匀性对树脂流动的影响[J]. 玻璃钢/复合材料, 2017(10):62-67. doi: 10.3969/j.issn.1003-0999.2017.10.011ZHAN Dong, YANG Rui, SUN Shiyong. Effect of fiber volume density heterogeneity on resin flow in RTM molding process[J]. Fiber Reinforced Plastics/Composites,2017(10):62-67(in Chinese). doi: 10.3969/j.issn.1003-0999.2017.10.011 [14] MAGAGNATO D, SEUFFERT J, BERNATH A, et al. Experimental and numerical study of the influence of integrated load transmission elements on filling behavior in resin transfer molding[J]. Composites Structures,2018,198:135-143. [15] LAWRENCE J M, FREY P, OBAID A A, et al. Simulation and validation of resin flow during manufacturing of compo-site panels containing embedded impermeable inserts with the VARTM process[J]. Polymer Composites,2007,28(4):442-450. doi: 10.1002/pc.20293 [16] BERTLING D, KAPS R, MULUGET A. Analysis of dry-spot behavior in the pressure field of a liquid composite molding process[J]. Aeronautical Journal,2016,7:577-585. doi: 10.1007/s13272-016-0207-2 [17] ARBTER R. Contribution to robust resin transfer molding[D]. Zurich Switzerland: Eidgenössische Technische Hochschule ETH Zürich, 2008. [18] 金世奇, 李文晓, 刘昊鑫. 缝合夹层结构复合材料树脂传递模塑成型工艺充模仿真[J]. 复合材料学报, 2018, 35(12): 3342-3349.JIN Shiqi, LI Wenxiao, LIU Haoxin. Filling simulation of stitched sandwich composite by resin transfer molding process[J]. Acta Materiae Compositae Sinica, 2018, 35(12): 3342-3349(in Chinese). [19] 王科, 赖家美, 鄢冬冬, 等. 缝合泡沫夹芯结构复合材料VARTM工艺树脂充填模拟及验证[J]. 高分子材料科学与工程, 2015, 31(11):124-129. doi: 10.16865/j.cnki.1000-7555.2015.11.025WANG Ke, LAI Jiamei, YAN Dongdong, et al. Process simulation and verification of stitched foam core sandwich structure by VARTM process[J]. Polymeric Materials Science and Engineering,2015,31(11):124-129(in Chinese). doi: 10.16865/j.cnki.1000-7555.2015.11.025 [20] JISHI H Z, UMER R, CANTWELL W J. Skin-core debonding in resin-infused sandwich structures[J]. Polymer Composites,2016,37(10):2974-2981. [21] YAN C, WU H L, REN X M, et al. Experimental and numerical study on the permeation behavior of foam-core sandwich panels in LCM[J]. Fibers and Polymers,2021,22(9):2612-2625. doi: 10.1007/s12221-021-0310-9 [22] JHAN Y T, LEE Y J, CHUNG C H. Resin flowing analysis in sandwich laminates under VARTM process[J]. Journal of Reinforced Plastics and Composites,2011,30(6):533-545. doi: 10.1177/0731684411399142 [23] JHAN Y T, LEE Y J, CHUNG C H. Experimental and numerical investigation of the VARTM process with a sandwich structure[J]. Journal of Composite Materials,2012,46(12):1417-1430. doi: 10.1177/0021998311418703 [24] 施赫荣, 王继辉, 倪爱清, 等. 穿孔泡沫夹芯复合材料灌注工艺仿真与方案优选[J]. 复合材料学报, 2023, 40(2):782-793. doi: 10.13801/j.cnki.fhclxb.20220323.001SHI Herong, WANG Jihui, NI Aiqing, et al. Simulation and optimization of infusion process for perforated foam sandwich composite[J]. Acta Materiae Compositae Sinica,2023,40(2):782-793(in Chinese). doi: 10.13801/j.cnki.fhclxb.20220323.001 [25] 雷波, 周持兴, 俞炜, 等. 泡沫夹芯结构板泡沫壁流道内的流动特性[J]. 化工学报, 2012, 63(3):775-780. doi: 10.3969/j.issn.0438-1157.2012.03.014LEI Bo, ZHOU Chixing, YU Wei, et al. Flow characteristics in foam wall channel of foam sandwich panel[J]. CIESC Journal,2012,63(3):775-780(in Chinese). doi: 10.3969/j.issn.0438-1157.2012.03.014 [26] 中华人民共和国国家质量监督检验检疫总局. 中国国家标准化管理委员会. 纤维增强塑料密度和相对密度试验方法: GB/T 1463—2005[S]. 北京: 中国标准出版社, 2005.General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China. Standardization Administration of the People's Republic of China. Fiber enhanced plastic density and relative density test methods: GB/T 1463—2005[S]. Beijing: Standards Press of China, 2005(in Chinese). [27] 穆文博, 严波. VARTM的边缘效应数值模拟研究[J]. 模具技术, 2022(2):1-7. doi: 10.3969/j.issn.1001-4934.2022.02.001MU Wenbo, YAN Bo. Numerical simulation study on the edge effect of VARTM[J]. Die and Mould Technology,2022(2):1-7(in Chinese). doi: 10.3969/j.issn.1001-4934.2022.02.001