连续纤维增强热塑性复合材料构件增材制造工艺力学及机制的多尺度模拟研究进展

燕鑫; 王莘儒; 刘思琴; 常保宁; 刘斐; 祝颖丹; 张武翔; 丁希仑

doi:10.13801/j.cnki.fhclxb.20240722.005

连续纤维增强热塑性复合材料构件增材制造工艺力学及机制的多尺度模拟研究进展

doi: 10.13801/j.cnki.fhclxb.20240722.005

燕鑫^{1, 2},
王莘儒¹,
刘思琴¹,
常保宁²,
刘斐^1, ,,
祝颖丹^3, ,,
张武翔^{1, 2, ,},
丁希仑^{1, 2}

1.
北京航空航天大学　机械工程及自动化学院，北京 100191
2.
北京航空航天大学宁波创新研究院高精尖制造技术与装备创新研究中心，宁波 315800
3.
中国科学院宁波材料技术与工程研究所，宁波 315201

基金项目: 国家自然科学基金(12372106；52205003)；浙江省自然科学基金(LD22E050011)；宁波市科技创新2025重大专项(2022Z070；2023Z054)

详细信息

通讯作者:
刘斐，博士，博士后，研究方向为复合材料成型工艺优化　E-mail: feiliulf@buaa.edu.cn

祝颖丹，博士，研究员，博士生导师，研究方向为复合材料制造及装备　E-mail: y.zhu@nimte.ac.cn

张武翔，博士，教授，博士生导师，研究方向为复合材料成型装备研制　E-mail: zhangwuxiang@buaa.edu.cn

中图分类号: V258; TB332
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- 文章访问数: 163
- HTML全文浏览量: 44
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- 被引次数: 0
出版历程
- 收稿日期: 2024-05-31
- 修回日期: 2024-06-27
- 录用日期: 2024-07-05
- 网络出版日期: 2024-07-23
- 刊出日期: 2024-09-15

Research progress in multi-scale modeling of processing mechanics and mechanism in additive manufacturing technology of continuous fiber reinforced thermoplastic composites

YAN Xin^{1, 2},
WANG Shenru¹,
LIU Siqin¹,
CHANG Baoning²,
LIU Fei^{1
, ,},
ZHU Yingdan^{3
, ,},
ZHANG Wuxiang^{1, 2
, ,},
DING Xilun^{1, 2}

1.
School of Mechanical Engineering and Automatic, Beihang University, Beijing 100191, China
2.
Ningbo Institute of Technology, Beihang University, Ningbo 315832, China
3.
Zhejiang Provincial Key Laboratory of Robotics and Intelligent Manufacturing Equipment Technology, Ningbo Institute of Material Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China

Funds: National Natural Science Foundation of China (12372106; 52205003); Zhejiang Provincial Natural Science Foundation of China (LD22E050011); Ningbo Key Projects of Science and Technology Innovation 2025 Plan (2022Z070; 2023Z054)

摘要

摘要: 连续纤维增强热塑性复合材料由于优异的力学和化学性能，具有广阔的应用前景。针对高性能复杂结构零件自动化制造需求，以自动铺放及连续纤维3D打印成型技术为代表的连续纤维增强热塑性复合材料的增材制造技术引起广泛关注。增材制造过程是一个包含多尺度、多物理场的复杂过程，工艺机制尚不明确，且热塑性聚合物具有熔点高、黏度大等特性，增大了加工难度，成型工艺控制极具挑战。由于成型过程包含一系列力学问题，采用多尺度工艺力学仿真，结合理论与实验研究可以构建成型工艺参数及成型工艺质量之间的关联，为优化工艺参数设计和装备模块设计提供理论支持。多尺度模拟工艺力学及机制研究涉及到对各类复杂物理现象的理解和捕捉，算法种类繁杂，模型构建难度大，使得多尺度工艺力学建模颇具挑战性。本文总结了近年来不同尺度模拟方法在自动铺放及连续纤维3D打印等连续纤维增强热塑性复合材料工艺机制研究方面的进展，并对未来的发展方向及应用前景进行了分析和展望。
- 连续纤维增强热塑性复合材料 /
- 增材制造 /
- 工艺力学 /
- 工艺机理 /
- 多尺度仿真
Abstract: Continuous fiber-reinforced thermoplastic composites offer exceptional mechanical and chemical properties, attracting widespread attention in both academia and industry. To meet the automation requirements for high-performance complex structural components, additive manufacturing technologies for continuous fiber-reinforced thermoplastic composites have garnered significant interest. These manufacturing methods include Fused Deposition Modeling and automated fiber placement. The additive manufacturing process involves multi-scale physical phenomena, presenting a complex interplay that is not yet fully understood. The inherent properties of thermoplastic polymers, such as their high melting points and viscosities, further complicate processing, posing substantial challenges in the control of manufacturing processes. Addressing the intricate mechanical challenges within the manufacturing process can be facilitated through the application of multi-scale process mechanics simulations. The integration of these simulations with theoretical and empirical research aids in forging a clear correlation between manufacturing process parameters and the quality of the final product. This provides theoretical support for optimizing process parameters and equipment module design. However, the implementation of multi-scale process simulation requires in-depth comprehension and precise description of physical phenomena. It also involves the design of sophisticated algorithms and the construction of intricate models, thereby increasing the difficulty and challenge of the simulation. This paper reviews recent studies employing various numerical modeling approaches to investigate the processing mechanisms of continuous fiber reinforced thermoplastic composites during the AFP and FDM processes. It also outlines potential promising directions in the field.
- continuous fiber-reinforced thermoplastic composites /
- additive manufacturing /
- process mechanics /
- process mechanism /
- multi-scale modeling

HTML全文

图 1 热塑性复合材料增材制造多尺度物理机制和工艺力学仿真方法^[9-16]

Figure 1. Multi-scale physical mechanisms and process mechanics simulation methods for additive manufacturing of thermoplastic composites^[9-16]

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图 2 (a)模块化铺丝机器人；(b)铺丝系统原理

Figure 2. (a) Modular AFP robot; (b) Principle of AFP system

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图 3 (a)FDM共挤出式打印原理；(b)FDM预浸料挤出式打印原理；(c)Markforged X7 3D 打印机^[28]；(d)、(e)西交研制FDM打印机^[29]；(f)、(g)三端进料式FDM打印机^[30]；(h)多轴FDM打印机原理；(i)多轴FDM打印机装置^[31-32]

Figure 3. (a) Principle of co-extrusion FDM printing; (b) Principle of prepreg extrusion FDM printing; (c) Markforged X3 3D printer machine^[28]; (d), (e) XJTU-developed FDM printer machine^[29]; (f), (g) Triple-extruder FDM printer machine^[30]; (h) principle of multi-axis FDM printer; (i) Multi-axis FDM printer machine^[31-32]

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图 4 连续纤维3D打印界面原子模型^[16]：(a)打印原理示意图；(b)原子模型构件思路及流程；(c)界面成型过程

Figure 4. Microscopic modeling of the interface in continuous fiber 3D printing^[16]: (a) Schematic diagram of the printing principle; (b) All-atom model of the interface; (c) Snapshots of the interface formation process

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图 5 连续纤维三维浸渍模型^[13]

Figure 5. Three-dimensional impregnation model of continuous fiber thermoplastic composite material in FDM process^[13]

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图 6 (a) FDM传热边界条件示意图^[36]；(b) AFP传热边界条件示意图^[83]

Figure 6. (a) Schematic diagram of thermal boundary conditions in the FDM model^[36]; (b) Schematic diagram of thermal boundary conditions in the AFP model^[83]

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图 7 复合材料增材制造的界面结合过程^[39]

Figure 7. Interfacial bonding process in additive manufacturing of composite materials^[39]

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图 8 FDM中界面结合过程中的孔洞缺陷示意图^[95]

Figure 8. Schematic diagram of void defects in the interfacial bonding process in FDM^[95]

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图 9 (a)自动铺放工艺的多尺度协同模拟^[98]；(b)连续纤维3D打印的多尺度优化模型^[99]

Figure 9. (a) Multi-scale modeling of the automated fiber placement process^[98]; (b) Multi-scale modeling of the 3D printing process^[99]

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图 10 基于3D打印制造技术的数字孪生应用框架^[112]

Figure 10. Digital twin framework based on 3D printing manufacturing technology^[112]

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