Wrinkles in fiber-reinforced resin composites: Micro-stress non-destructive testing
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摘要: 纤维增强树脂复合材料在制造和服役过程中会不可避免地产生各类缺陷，且缺陷种类多、特征尺寸分散，检测难度大。缺陷检测的最终目的是对含缺陷构件的机械力学性能给出适应性评价，为此提出了一种特别适合于纤维增强树脂复合材料的集缺陷检测和性能评价为一体的微应力无损检测方法。该方法对构件施加一定的载荷使其处于微应力状态，结合全场位移的光学测量技术，捕捉缺陷导致的异常响应，以褶皱缺陷为例给出了具体的实施过程。首先基于褶皱缺陷特征响应的预测结果设计了特定的检测方案，并基于光栅投影测量技术创新性地提出了一种测量离面位移的新方法。试验结果表明，在轴向微应力加载下，利用提出的光栅投影测量方法可以探测到褶皱缺陷导致的离面位移畸变，畸变的位置和大小反映了缺陷的位置和严重程度。同时由于使用了光-力学的综合检测方法，可以跨越对缺陷具体形貌尺寸的探查，直接获得含缺陷构件在给定工况下的力学行为响应，为构件适应性评价提供参考依据。
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关键词:
- 纤维增强树脂复合材料 /
- 褶皱缺陷 /
- 特征响应 /
- 光栅投影 /
- 无损检测
Abstract: Various defects with dispersive feature sizes can be accumulated inevitably in fiber-reinforced resin composites during their manufacturing and service processes, which are also difficult to be detected. The final objective of defects testing is to obtain the accuracy assessment of performance of defective structures. A micro-stress non-destructive defect detection and evaluation method is proposed for fiber-reinforced resin composites, which is especially suitable for composites measurement. Combing with the optical measurement technology for full-field displacement, the abnormal responses which caused by the defects of the structure under low stress level is able to be captured. The wrinkle defect detection is taken as an example to show the measurement processes. First, a specific detection scheme is designed based on the theoretical prediction of characteristic responses of wrinkles. Then, a new method of full-field displacement measurement is innovatively proposed based on the grating projection technology. Results show that under the axial tensile loading, the distorted out-of-plane displacements caused by wrinkles can be detected by the improved grating projection technology. The distorted displacements revealed the spatial distribution and severity of defects, and the influence on structural performance degradation can be evaluated based on the degree of displacement distortion. Further, by applying the optical-mechanical detection method, the mechanical responses of the defective component under a given working condition can be obtained directly, which can provide a reference for the adaptability evaluation of the component. -
图 1 纤维增强树脂复合材料均匀型褶皱
Figure 1. Uniform wrinkle in fiber-reinforced resin composites
A—Fiber waviness; λ—Wavelength
图 2 纤维增强树脂复合材料中含均匀型褶皱的RVE等效刚度计算模型
Figure 2. Calculation model of equivalent stiffness of RVE with uniform wrinkle in fiber-reinforced resin composites
Cij—Ply stiffness matrix; C*—Equivalent stiffness matrix of wrinkle-free laminates; C**—Equivalent stiffness matrix of laminates with uniform wrinkle; θk—Orientation angle of kth ply; φ—Out-of-plane misalignment
图 3 含分散性褶皱的纤维增强树脂复合材料薄板模型
Figure 3. Thin plate model for fiber-reinforced resin composites with dispersed wrinkles
图 4 CF/EP复材层合板的不同加载方式
Figure 4. Schematic of different loading modes for CF/EP composite laminates
σx—Axial tensile stress; My—Bending moment; τxy—Shearing stress
图 5 含随机褶皱缺陷的CF/EP复材层合板拉伸位移响应
Figure 5. Displacement responses of CF/EP composite laminates with randomly dispersed wrinkle defects under tensile load
u—In-plane displacement in x-direction; v—In-plane displacement in y-direction; w—Out-of-plane displacement in z-direction
图 6 无缺陷的CF/EP复材层合板拉伸位移响应
Figure 6. Displacement responses of pristine CF/EP composite laminates under tensile load
u—In-plane displacement in x-direction; v—In-plane displacement in y-direction; w—Out-of-plane displacement in z-direction
图 7 含随机褶皱缺陷的CF/EP复材层合板弯曲位移响应
Figure 7. Displacement responses of CF/EP composite laminates with randomly dispersed wrinkle defects under bending load
u—In-plane displacement in x-direction; v—In-plane displacement in y-direction; w—Out-of-plane displacement in z-direction
图 8 无缺陷的CF/EP复材层合板弯曲位移响应
Figure 8. Displacement responses of pristine CF/EP composite laminates under bending load
u—In-plane displacement in x-direction; v—In-plane displacement in y-direction; w—Out-of-plane displacement in z-direction
图 9 含随机褶皱缺陷的CF/EP复材层合板剪切位移响应
Figure 9. Displacement responses of CF/EP composite laminates with randomly dispersed wrinkle defects under shearing load
图 10 无缺陷的CF/EP复材层合板剪切位移响应
Figure 10. Displacement responses of pristine CF/EP composite laminates under shearing load
图 11 钢棒法制作含褶皱缺陷的CF/EP复材层合板试样
Figure 11. Wrinkled specimen of CF/EP composite laminates made with steel bar method
图 13 CF/EP试样Ⅰ与无缺陷CF/EP试样离面位移有限元结果对比
Figure 13. Comparison of finite element results on out-of-plane displacement between CF/EP specimen Ⅰ and wrinkle-free CF/EP specimen
图 14 三维点云重构算法提取离面位移
Figure 14. Schematic diagram of point cloud data reconstruction algorithm.
图 15 含褶皱缺陷的CF/EP复材层合板试样测试装置示意图
Figure 15. Schematic diagram of the test device of wrinkled specimen of CF/EP composite
图 16 CF/EP试样I的加载前后三维点云
Figure 16. 3D point cloud of CF/EP specimen I before and after loading
图 19 CF/EP复材层合板离面位移及位移比随波纹比的变化
Figure 19. Normalized out-of-plane displacement and displacement ratio various with wrinkle ratio of CF/EP composite laminates
图 20 CF/EP复材层合板离面位移及位移比随载荷的变化
Figure 20. Normalized out-of-plane displacement and displacement ratio various with applied node force of CF/EP composite laminates
表 1 碳纤维(CF)/环氧树脂(EP)复合材料弹性参数
Table 1. Elastic parameters of carbon fiber (CF)/epoxy (EP) composites
E11 /GPa (E22 /E33) /GPa G23 /GPa G31 /GPa G12 /GPa ν21 ν32 ν31 133.3 9.09 3.16 7.24 7.23 0.261 0.436 0.261 Notes: E11, E22, E33—Elastic modulus (direction 11, 22, 33); G12, G23, G31—Shear modulus (direction 12, 23, 31); v21, v32, v31—Poisson’s ratio (direction 21, 32, 31). 
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表 2 CF/EP复材层合板中褶皱缺陷对不同载荷的响应敏感性
Table 2. Response sensitivity of wrinkle defects to different loading modes in CF/EP composite laminates
Loading mode Uniaxial tensile Bending Shearing Response sensitivity In-plane displacement u 
v 
Out-of-plane displacement w Note: *Sensitivity: 表 3 CF/EP复材层合板中层间弱粘结缺陷对不同载荷的响应敏感性[30]
Table 3. Response sensitivity of weak bonding defects to different loading modes in CF/EP composite laminates
Loading mode Uniaxial tensile Bending Shearing Response sensitivity In-plane displacement u v Out-of-plane displacement w
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表 4 CF/EP试样中的缺陷参数
Table 4. Defect parameters of the CF/EP specimens
Specimen number Layup sequences Wrinkle parameters Wavelength/mm Amplitude/mm Wrinkle ratio I [0/90/0/90]s 6.0 1.2 0.200 II [0/90/0/90]s 12.0 0.8 0.067
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表 5 CF/EP试样离面位移实测结果与有限元结果比较
Table 5. Comparison of out-of-plane displacement of CF/EP specimens between measurement results and finite element results
Specimen number Load/N Measurement results/cm Finite element results/cm Error I 200 0.01078 0.0089 17.7% 500 0.01806 0.0154 14.7% 800 0.02093 0.0193 7.8% 1 000 0.02359 0.0212 10.1% 1 200 0.02508 0.0228 10.0% Ⅱ 200 0.00218 0.0027 20.1% 500 0.00918 0.0101 8.6% 1 200 0.01361 0.0115 18.3%
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