Investigation on the influence of winding tension on residual stress and spring-in deformation of dry wound composite structure
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摘要:
缠绕张力是影响复合材料缠绕结构服役前残余应力分布和结构效率的关键因素。预测固化后结构内残余应力分布是开展缠绕张力制度设计和成型工艺优化的重要基础。目前多数缠绕结构服役前残余应力分析简化为只考虑缠绕过程张力放松机制，而忽略固化过程影响。作者认为要实现缠绕结构服役前预应力设计必须综合考虑缠绕和固化两个过程，评估缠绕张力与固化应力对服役前残余应力的影响机制。为此，本文开展了缠绕张力对缠绕复合材料结构残余应力的影响研究，为便于测量，借助切割释放圆筒内部残余应力，通过测量回弹变形对固化后内部残余应力分布进行表征，提出并验证了顺次开展纤维缠绕与固化过程残余应力分析的重要性。实验方面，采用干法缠绕工艺基于Q235钢芯模和PA6芯模分别制备了恒定张力(40N)、内松外紧(20N-40N-60N)和内紧外松(60N-40N-20N)3种不同张力制度的复合材料缠绕圆筒，通过测试切割过程的应变释放与回弹变形实现了内部残余应力的对比分析；数值分析方面，基于ABAQUS软件，建立了复合材料圆筒缠绕和固化过程顺次分析数值模型，对内部残余应力和切割回弹变形进行预测。结果表明：固化应力与缠绕张力均对总残余应力产生贡献，但由于固化过程剩余缠绕张力进一步放松，固化后总残余应力水平低于缠绕残余应力与固化应力线性叠加之和。固化过程不会改变缠绕张力对最终残余应力分布的影响规律；缠绕张力对总残余应力的影响程度与芯模材质相关，芯模热变形越大，缠绕张力的影响越弱。当采用相同芯模时，内松外紧(20N-40N-60N)张力制度产生的切割回弹角最小，内紧外松(60N-40N-20N)张力制度产生的回弹角最大；当采用相同张力制度时，基于PA6芯模制备的缠绕圆筒切割试样回弹角远大于基于钢芯模制备的缠绕圆筒试样。 基于钢芯模和PA6芯模的不同张力制度缠绕圆筒的回弹角实验值与仿真值对比 Abstract: The evaluation of residual stress after winding and curing process is the basement for the optimization design of winding process scheme and the achievement of pre-service stressing design. In this paper, three kinds of winding tension strategies, e.g. constant tension (40N), loose inside and tight outside tension (20N-40N-60N), and tight inside and loose outside tension (60N-40N-20N), were used to prepare the composite winding cylinders on the steel mould and PA6 mould by the dry winding process, respectively. The internal residual stresses were analyzed by measuring the released strain and spring-in angle during cutting process. With the aid of element birth and death technique, numerical model of the layer-by-layer winding process were created and the distributions of residual stress during winding were calculated. Subsquently, the curing process was simulated based on the constitutive model of CHILE (Tg). The after-curing residual stress and after-cutting spring-in deformation were predicted. It is shown that both the curing stress and the winding tension stress contribute to the total residual stresses. However, due to the further releasing of winding residual tension during the curing process, the total residual stresses are lower than the sum of the winding residual stresses and curing residual stresses. The impact of the winding tension strategies on total residual stresses is not affected by curing operation. The contribution of winding tension to the total residual stress is affected by the mould material used. The larger thermal deformation of the mould, the weaker the influence of winding tension strategy. For the situations with same mould, the winding cylinder with loose inside and tight outside (20N-40N-60N) tension strategy shows the smallest after-cutting spring-in angle and the one with tight inside and loose outside (60N-40N-20N) tension strategy shows the largest after-cutting spring-in angle. For the cases with same tension strategy, the winding cylinders made on PA6 mould give much larger after-cutting spring-in angle than that made on steel mould.-
Key words:
- dry winding /
- winding tension strategy /
- residual stress /
- spring-in deformation /
- numerical model
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图 1 基于钢芯模(a)和PA6芯模(b)的缠绕圆筒干法制备过程
Figure 1. Dry winding process of cylinders made on steel mould (a) and PA6 mould (b)
图 3 缠绕圆筒切割前(a)和切割后(b)示意图
Figure 3. Schematic diagram of wound cylinder before (a) and after (b) cutting
图 4 半径法计算回弹角示意图
Figure 4. Schematic diagram of the spring-in angle calculated by the radius method
图 5 SS58#-12KHF30F预浸料动态DSC测试曲线
Figure 5. Dynamic DSC test curves of SS58#-12KHF30F prepreg
图 6 SS58#-12KHF30F预浸料旋转流变仪测试曲线
Figure 6. Test results of rotary rheometer for SS58#-12KHF30F prepreg
图 8 SS58#-12 KHF30 F预浸料瞬态玻璃化转变温度与固化度关系
Figure 8. Relationship between transient glass transition temperature and curing degree of SS58#-12 KHF30 F prepreg
图 9 SS58#-12KHF30F预浸纱的树脂储能模量随温度变化关系
Figure 9. Relationship between storage modulus and temperature of resin for SS58#-12KHF30F prepreg yarn
图 10 TMA测试的SS58#-12 KHF30 F预浸纱完全固化试样横向热膨胀系数(a)和纵向热膨胀系数(b)
Figure 10. Data of transverse thermal expansion coefficient (a) and longitudinal thermal expansion coefficient (b) of SS58#-12 KHF30 F prepreg cured sample tested by TMA
图 11 缠绕-固化过程数值分析流程图
Figure 11. Flow chart of numerical analysis of winding - curing process
图 12 钢芯模(a)和PA6芯模(b)缠绕圆筒有限元分析模型
Figure 12. Finite element models of wound cylinder based on steel mould (a) and PA6 mould (b)
图 13 不同缠绕张力制度下钢芯模缠绕圆筒(a) 和PA6芯模缠绕圆筒(b) 缠绕后环向应力分布
Figure 13. Distribution of hoop stress after winding of steel mold winding cylinder (a) and PA6 mold winding cylinder (b) under different winding tension regimes
图 14 固化过程复合材料层的温度、固化度和弹性模量E33随时间变化曲线
Figure 14. Variation of temperature, curing degree and elastic modulus E33 of composite layer during the curing process
图 15 不同张力制度的缠绕试样固化-切割过程中环向应变变化模拟结果：(a) S1；(b)S2；(c)S3
Figure 15. Simulated hoop strain variations of winding samples made with different tension strategies during curing and cutting process: (a) S1; (b)S2; (c)S3
图 16 钢芯模(a)和PA6芯模(b)表面制作圆筒试样固化后内部环向应力分布
Figure 16. Variations of hoop stress distribution after curing for winding cylinders made on steel mould (a) and PA6 mould (b)
图 17 不同缠绕圆筒回弹角的实验值与仿真值
Figure 17. Experimental and simulated values of spring-in angle of different winding cylinders
表 1 不同张力制度的缠绕圆筒每层的缠绕张力
Table 1. Winding tension of each layer of the winding cylinder with different tension strategies
Layers S1/N S2/N S3/N 1-3 40 20 60 4-6 40 40 40 7-9 40 60 20 Notes: S1, S2 and S3 are the 40 N constant tension, the variable tension from 20 N to 60 N and the variable tension from 60 N to 20 N. 
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表 2 钢芯模和PA6芯模制备的不同张力制度缠绕圆筒内外表面应变变化
Table 2. Changes of inner and outer surface strain of the cylinder wound with different tension strategies on steel mould and PA6 mould
Winding tension Mould Router/10−6 Rinner/10−6 S1 Steel 272±8 −276±4 PA6 1367±7 −1332±9 S2 Steel 127±5 −123±2 PA6 1178±10 −1225±9 S3 Steel 451±4 −440±5 PA6 1452±9 −1481±6 Notes: Router and Rinner are the average value of the strain for strain gauges R1, R2 and R3 and the value for strain gauges R4, R5 and R6.
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表 3 钢芯模和PA6芯模制备的不同张力制度缠绕圆筒回弹角
Table 3. Spring-in angle of the cylinders wound with different tension strategies on steel mould and PA6 mould
Winding tension Mould Spring-in angle /(°) S1 Steel 6.23±0.1 PA6 25.45±0.2 S2 Steel 2.43±0.1 PA6 22.65±0.2 S3 Steel 8.58±0.2 PA6 28.39±0.2
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表 5 不同缠绕张力对应的纤维方向等效应力
Table 5. Equivalent longitudional stress of different winding tensions
b/mm h/mm F/N S11/MPa 4.5 0.16 20 27.78 40 55.55 60 83.33 Notes: b —Bandwidth of Prepreg yarn; h — Thickness of Prepreg yarn; F — Winding tension in prepreg yarn; S11 — Stress in the fiber direction.
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表 6 SS58#-12KHF30F预浸纱用T700级碳纤维的力学性能参数
Table 6. Mechanical properties of T700 grade carbon fiber for SS58#-12KHF30F prepreg yarn
Parameter Value E1 f /GPa 232 E2 f =E3 f /GPa 15 v12 f =v13 f 0.28 v23 f 0.49 G12 f =G13 f /GPa 24 G23 f /GPa 5.03
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表 7 芯模材料参数
Table 7. Material parameters of mandrels
parameters Steel PA6 E/MPa 210000 2320 v 0.33 0.34 αEXP/10−6K−1(20-60℃) 12 90.41 αEXP/10−6K−1(60-120℃) 12 156.7 Notes: E — Young modulus; v — Poisson’s ratio; αEXP — Coefficient of thermal expansion.
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表 8 不同缠绕圆筒在切割过程内、外表面应变变化的实验值与仿真值
Table 8. Experimental and simulated values of the cutting-released strains on the inner and outer surfaces of the different winding cylinders
Tension strategy Mould Router Rinner Experimental
value /10−6Simulated
value /10−6Error /% Experimental
valueSimulated
value /10−6Error /% S1 Steel 272 245 −9.93 −276 −259 −6.16 PA6 1367 1210 −11.49 −1332 −1218 −8.56 S2 Steel 127 116 −8.67 −123 −119 −3.25 PA6 1178 1070 −9.17 −1225 −1075 −12.24 S3 Steel 451 405 −10.20 −440 −411 −6.59 PA6 1452 1327 −8.60 −1481 −1335 −9.86 Notes: Router is the average strain of positions on R1, R2 and R3, Rinner is the average strain of positions on R4, R5 and R6.
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