Full-field fiber trajectory motion simulation and distribution verification of complex components based on three-dimensional winding technology
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摘要: 三维缠绕技术是一种新兴的复合材料预成型体制造技术，可以通过机器人辅助缠绕解决复杂芯模大角度纤维铺放难题，在一定长度内对任意几何形状芯模做环形缠绕。但是三维缠绕的控制方式还不成熟，对异型芯模的缠绕轨迹较为复杂，所得的纤维轨迹也难以预测。经过对三维缠绕纤维沉积过程的研究，采用运动学仿真法建立三维缠绕仿真模型，实现对三维缠绕纤维轨迹的快速预测。首先对异型芯模进行网格重构，提升了仿真的精度；然后利用空间离散点位模拟围绕复杂芯模时丝嘴的运动轨迹；最后利用纤维沉积机制作为判据，实现仿真纤维轨迹的迭代更新。三维缠绕仿真模型有两个主要输入参数：旋转环步进距离与旋转环偏转角度。通过现场试验验证，步进距离增大时，芯模的面密度会稳定降低，旋转环的动态偏转也会直接影响到弯曲芯模内外侧纤维轨迹。对直芯模进行运动学仿真所得试验结果与纤维沉积理论计算值对比，误差小于0.2%。理论与实践相结合的研究证明了运动学仿真法对三维缠绕技术仿真的可靠性与准确性。Abstract: As an emerging composite preform manufacturing technology, three-dimensional winding technology can solve the problem of large-angle fiber placement for complex core molds and make circular winding for core molds with arbitrary shapes within a certain length by robot-assisted winding. However, the control method of 3D winding is still immature, the winding trajectory of the shaped core mold is complicated, and the resulting fiber structure is difficult to predict. After the study of 3D winding fiber deposition process, the kinematic simulation method was used to establish a 3D winding simulation model to realize the fast prediction of 3D winding fiber structure. Firstly, the mesh reconstruction of the shaped mandrel was carried out to improve the accuracy of the simulation; then the spatial discrete point positions were used to simulate the motion trajectory of the filament nozzle around the complex mandrel, and finally the fiber deposition mechanism was used as a criterion to achieve the iterative updating of the simulated fiber structure. The 3D winding simulation model has two main control parameters: the step and the deflection angle of the rotary head. It is verified through experiments that the surface density of the mandrel decreases when the step increases, and the dynamic deflection of the rotary head directly affects the inner and outer fiber structure of the curved mandrel. The experiment results obtained from the simulation of the straight mandrel are compared with the theoretically calculated values, and the error is less than 0.2%. The reliability and accuracy of the kinematic simulation method for the simulation of 3D winding technology is proved by the combination of theoretical and practical research.
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图 4 (a)对不规则网格模型等距切片；(b)模型切片后得到的表面轮廓点位；(c)利用点位重构网格；(d)对其他形状芯模进行网格重构
Figure 4. (a) Equally spaced slicing of an irregular mesh model; (b) Surface contour point locations obtained after slicing the model; (c) Reconstruction of the mesh using the point locations; (d) Mesh reconstruction for other shapes of core molds
图 5 (a)变截面芯模表面向量场标定；(b)弯曲芯模表面向量场
Figure 5. (a) Calibration of the surface vector field of the variable-section mandrel; (b) Surface vector field of the bending mandrel
图 6 (a)切片距离为10 mm时纤维间距变化；(b)切片距离为0.01 mm时纤维间距变化
Figure 6. (a) Variation of fiber spacing at slicing distance of 10 mm;(b) Variation of fiber spacing at slicing distance of 0.01 mm
图 7 旋转环与轨迹保持垂直时丝嘴轨迹计算方法
Figure 7. Calculation of filament nozzle trajectory when the rotating ring is kept perpendicular to the trajectory
图 8 旋转环与轨迹发生偏转时丝嘴轨迹计算方法
Figure 8. Calculation method of filament nozzle trajectory in the event of deflection of the rotating ring from the trajectory
图 10 (a)矩形直管直螺旋缠绕仿真；(b)矩形直管斜螺旋缠绕仿真；(c)矩形弯管螺旋缠绕仿真；(d)矩形直管直螺旋缠绕沉积点与几何尺寸；(e)矩形直管斜螺旋缠绕沉积点与几何尺寸；(f)在矩形弯管上仿真的沉积纤维
Figure 10. (a) Rectangular straight tube positive helical winding simulation; (b) Rectangular straight tube inclined helical winding simulation; (c) Rectangular bent tube helical winding simulation; (d) Rectangular straight tube positive helical winding deposition point and geometry; (e) Rectangular straight tube inclined helical winding deposition point and geometry; (f) Deposited fibers simulated on a rectangular bent tube
图 11 (a)面密度与间距计算方法；(b)曲面纤维间距计算方法
Figure 11. (a) Calculation of surface density and spacing; (b) Calculation of surface fiber spacing
图 12 (a) PQArt软件仿真机器人轨迹；(b)现场试验三维缠绕；(c)芯模尺寸与采样点
Figure 12. (a) PQArt software simulation of robot trajectory; (b) Field experiment 3 D winding; (c) Mandrel size and sampling points
图 13 对原始芯模网格进行仿真预测的纤维内外侧面密度分布
Figure 13. Density distribution of inner and outer fiber flanks predicted by simulation of the original mandrel mesh
图 14 变步进$P$与偏转角度$ {\theta _h} $的三维缠绕仿真结果与试验结果对比
Figure 14. Comparison of simulation and experimental results of 3D winding with variable step $P$ and deflection angle $ {\theta _{\text{h}}} $
图 15 $ {\theta _h} $在芯模A、B段均匀增减时内外侧纤维面密度变化趋势
Figure 15. Trend of inner and outer fiber surface density at $ {\theta _h} $ uniform increase and decrease in core A and B parts
表 1 矩形四面的缠绕角仿真与数值计算对比
Table 1. Comparison between simulation and numerical calculation of winding angle for rectangular four faces
Face numbering Straight spiral track winding Inclined spiral track winding Theoretical/(°) Simulation/(°) Error/% Theoretical/(°) Simulation/(°) Error/% 1 88.1757 88.1763 6.805×10−4 98.1945 98.2026 8.249×10−3 2 88.2578 88.2608 3.399×10−3 88.2141 88.2579 4.965×10−2 3 88.1757 88.1763 6.805×10−4 78.2557 78.2361 −2.505×10−2 4 88.2578 88.2608 3.399×10−3 88.2141 88.3281 0.1292 
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