某T1000级碳纤维缠绕复合材料壳体承压特性

金书明; 李德华; 杨明; 林天一; 许辉; 龚耀华; 张烜维

某T1000级碳纤维缠绕复合材料壳体承压特性

上海航天动力技术研究所, 上海 201109

详细信息

通讯作者:
杨明，硕士，高级工程师，研究方向为固体火箭发动机结构设计　E-mail: pj_yangm@163.com

中图分类号: TB332
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- HTML全文浏览量: 17
- 被引次数: 0
出版历程
- 收稿日期: 2024-01-23
- 修回日期: 2024-03-21
- 录用日期: 2024-03-22
- 网络出版日期: 2024-04-24

Pressure-sinkage characteristics of a T1000 carbon fiber wound composite case

Shanghai Aerospace Power Technology Research Institute, Shanghai 201109, China

摘要

摘要: 为探究T1000级高压强复合材料壳体承压力学特性，本文开展了国产T1000级碳纤维复合材料宏观力学性能横向对比测试，并以此为基础完成复合壳体材料选型，根据工艺铺层信息，结合三次样条厚度预测方法及非测地线缠绕角计算方法，实现壳体的高保真有限元建模，并基于渐进损伤分析方法，对复合壳体封头应力应变响应、复合壳体损伤演化过程、失效模式及爆破压强进行预示，最终通过液压强度试验验证了计算模型的准确性。结果表明：国产T1000碳纤维性能与东丽T1000G相当，且拓展CCF1000S综合性能表现最佳；封头段由壳体与金属接头段刚度不连续引起的变形不协调使得该区域受弯曲、拉剪耦合作用，进而导致封头肩部应力水平明显高于两侧；基于三维Hashin损伤准则的渐进损伤模型能有效地描述壳体损伤与失效过程，更能准确地预测壳体爆破压强及破坏位置。
- T1000碳纤维 /
- 纤维缠绕 /
- 复合材料壳体 /
- 静力分析 /
- 渐进损伤分析
Abstract: In order to study the pressure-sinkage characteristics of T1000 carbon fiber reinforced composite case, transverse comparative tests of macroscopic mechanical properties of domestic T1000 carbon fiber composite were carried out in this paper. On the basis, the selection of the composite materials was implemented. The high precision finite element model of the composite case was established based on the layup in the process, cubic spline thickness prediction method and non-geodesic theory. The stress-strain response of the composite case dome was calculated, and the damage evolution of the composite case, the failure mode and the burst pressure were predicted based on the progressive damage analysis method. Finally, the simulation model was validated by hydraulic tests. The results show that the performance of domestic T1000 carbon fiber is equivalent to Toray T1000G, and the comprehensive performance of CCF1000S is the best. The deformation disharmony caused by the stiffness discontinuity between the case and the metal boss makes the dome part subject to the coupling effects of bending, tension and shear, which results in the stress level of the dome shoulder being obviously higher than that on both sides. The progressive damage model based on the 3D Hashin damage criterion can effectively describe the damage and failure process of the case, and predict the bursting pressure and failure location of the case more accurately.
- T1000 carbon fiber /
- filament winding /
- composite case /
- static analysis /
- progressive damage analysis

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图 1 试验测试过程

Figure 1. Experimental testing process

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图 2 标准壳体试后残骸

Figure 2. Test wreckage of composite cases

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图 3 螺旋缠绕层角度变化

Figure 3. Winding angle variable of helical winding layers

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图 4 有限元计算模型

Figure 4. Finite element model of the composite case

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图 5 有限元模型边界条件

Figure 5. Boundary conditions of the finite element model

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图 6 渐进损伤计算流程

Figure 6. Progressive damage calculation process

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图 7 碳纤维缠绕复合材料壳体在工作压力(25 MPa)作用下应力、应变计算结果

Figure 7. Strain/stress simulation results of carbon fiber wound composite case under working pressure (25 MPa)

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图 8 不同内压作用下复合材料壳体封头段应力计算结果

Figure 8. Simulation stress in the dome of composite case under different internal pressures

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图 9 复合材料壳体工作压强下(25 MPa)封头段位移计算结果

Figure 9. Displacement calculation under working pressure(25 MPa) of composite case dome part

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图 10 碳纤维缠绕复合材料壳体渐进损伤计算结果

Figure 10. Damage progressive analysis results of carbon fiber wound composite case

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图 11 壳体筒段特征点的内压-位移计算结果

Figure 11. Pressure-displacement calculation of the composite case cylinder characteristic points

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图 12 复合材料壳体应变测点分布

Figure 12. Distribution of strain gauges of composite case

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图 13 复合材料壳体液压加载曲线

Figure 13. Curve of hydraulic pressure of composite case

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图 14 复合材料壳体液压爆破结果

Figure 14. Results of hydraulic burst test of composite case

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图 15 复合材料壳体液压加载时时间-应变曲线

Figure 15. Time-strain curves of composite case under hydraulic loading

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图 16 复合材料壳体工作压强下应变计算-实测结果对比

Figure 16. Strain comparison between simulation and test results under working pressure of composite case

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表 1 碳纤维原丝性能

Table 1. Performance of T1000 carbon fiber precursor

Parameter	T1000GB	CCF1000S	HF50S
Tensile strength/MPa	6370	6370	6500
Tensile modulus/GPa	294	280	295
Breaking elongation/%	2.2	1.8	2.0

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表 2 碳纤维复丝性能(MPa)

Table 2. Performance of carbon fiber strands (MPa)

Specimens	T1000 GB	CCF1000 S	HF50 S
1#	6352	6479	6127
2#	6132	6395	6333
3#	6256	6785	6586
4#	6285	6643	6221
5#	6392	6673	6109
Average value	6283	6595	6275
Discrepancy	1.5%	2.4%	3.1%

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表 3 CR-160 H树脂浇筑体性能

Table 3. Performance of CR-160 H epoxy resin cast

Parameter	Value
Tensile strength/MPa	50.3
Tensile modulus/GPa	3.2
Breaking elongation/%	≥1.2

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表 4 T1000复合材料/CR-160 H复合材料力学性能参数

Table 4. Mechanical properties of T1000/CR-160 H composite

Parameter	T1000GB	CCF1000S	HF50S
Unidirectional composite laminates
Tensile modulus，E₁/GPa	168	154	150
Transverse tensile modulus，E₂=E₃/GPa	9.8	7.9	7.8
In-plane Poisson's ratio，µ₁₂=µ₁₃	0.33	0.31	0.34
Out-plane Poisson's ratio，µ₂₃	—	0.46	—
In-plane shear modulus，G₁₂=G₁₃/GPa	5.52	4.61	4.53
Inter laminar shear modulus，G₂₃/GPa	—	2.91	—
Longitudinal tensile strength，X_t/MPa	2830	2990	2740
Longitudinal compressive strength，X_c/MPa	1035	1076	1127
Transverse tensile strength，Y_t/MPa	29.5	30	32
Transverse compressive strength，Y_c/MPa	132	120	129
In-plane shear strength，S/MPa	83	84	94
Fiber volume fraction，V_f/%	59.67	60.50	65.67
NOL rings
Tensile strength，X_t/MPa	3225	3415	3179
Inter-laminar shear strength，S/MPa	58	48	56

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表 5 标准壳体爆破结果/MPa

Table 5. Blasting results of standard case

Composite cases	T1000 GB	CCF1000 S	HF50 S	SYT55
1#	36	36.5	34.5	30.5
2#	36.5	37	36	31
3#	35.5	37	35	29
Average value	36	36.8	35.2	30.2
Discrepancy	1.4%	0.7%	2.2%	3.4%

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表 6 缠绕层厚度估算结果

Table 6. Thickness prediction of filament winding layers

Parameter	Value
Nominal value of helical winding angle，α/(°)	30
Thickness of winding layer/mm	0.16
Number of helical winding layers	14
Number of circumferential winding layers	11

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表 7 缠绕层工艺参数

Table 7. Process parameters of winding layer

Parameter	Value
Winding angle of front equator，α/(°)	20.6
Winding angle of after equator，α/(°)	42.6
Thickness of helical winding layer/mm	0.148
Thickness of circular winding layer/mm	0.121
Number of helical winding layers	16
Number of circular winding layers	16

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表 8 材料性能

Table 8. Mechanical properties

Parameters	TC4	Steel	Rubber
Elastic modulus，E/GPa	123	196	0.1
Poisson's ratio，µ	0.3	0.3	0.49
Yield strength，σ_s/MPa	825	875	-
Tensile strength，σ_b/MPa	895	1070	14

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表 9 CF8611/CR-160H材料性能

Table 9. Mechanical properties of CF8611/CR-160H

Parameters	Value
Tensile modulus，E_x=E_y/GPa	89.4
Tensile modulus of thickness direction，E_z/GPa	9.1
Poisson's ratio，µ_xy	0.32
Poisson's ratio，µ_xz=µ_yz	0.49
Shear modulus，G_xy /GPa	6.3
Shear modulus，G_xz =G_yz/GPa	3.7

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表 10 材料性能退化准则

Table 10. Composite material degradation criteria

Failure mode	Degradation criterion
Failure mode	E₁₁	E₂₂	E₃₃	μ₁₂	μ₁₃	μ₂₃	G₁₂	G₁₃	G₂₃
Tensile failure of matrix	1	0.2	—	—	—	—	0.2	—	0.2
Compression failure of matrix	—	0.4	—	—	—	—	0.4	—	0.4
Tensile failure of fiber	0.07	0.07	0.07	0.07	0.07	0.07	0.07	0.07	—
Compression failure of fiber	0.14	0.14	0.14	0.14	0.14	0.14	0.14	0.14	—

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表 11 复合材料壳体计算误差分析

Table 11. Calculation error analysis of composite case

Measure points	1#	2#	3#	4#	5#
Circumferential strain/×10^-6
Simulation results	4806	12670	11770	10470	786
Test results	4018	11720	10780	9960	650
Error/%	19.61	8.11	9.18	5.12	20.92
Axial strain/×10^-6
Calculate value	7412	4421	4227	4459	6941
Measured value	6907	5465	5320	4845	7495
Deviation/%	7.31	-19.10	-20.55	-7.97	-7.39

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