Advances in forming and numerical simulation research of tufted composite preforms
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摘要: 三维复合材料因其优异的抗分层能力,在航空航天等领域具有巨大的应用价值,近年来受到了国内外研究者的广泛关注。然而,传统三维复合材料制造周期长,工艺复杂度高,曲面成形难度大,已成为制约三维复合材料构件应用推广的关键难题之一。Tufting缝合(亦称“簇绒缝合”)是一种工艺简单的单边缝合技术,其缝合线非互锁的结构特征使Tufting缝合后的三维预制体在曲面上无缺陷成形变为可能。本文首先对Tufting缝合工艺的发展历程和Tufting缝合复合材料的结构特征进行了概述,其次梳理了现有关于Tufting缝合预制体曲面模压成形方面的研究,重点从成形性能分析、成形缺陷定义和数字化表征手段三个方面,指出了目前研究所取得的进步和尚缺少的不足,并对Tufting缝合预制体曲面模压成形的数值模拟方法进行了总结,点明了Tufting缝合预制体成形模型的特殊性,最后展望了Tufting缝合技术在复合材料预制体成形领域未来的发展方向。Abstract: Three-dimensional composite materials have great application value in aerospace and other fields due to their excellent anti-delamination capability. In recent years, they have attracted extensive attention from domestical and abroad researchers. However, for the traditional three-dimensional (3D) composite materials, they require long manufacturing cycles, complex manufacturing technique and are hard to be formed. This has become one of the key challenges restricting the broad application of the 3D composite components. Tufting is a simple single-sided stitching technique characterized by non-interlocked structure. This feature probably allows three-dimensional preforms made by tufting to be shaped on curved surfaces without defects. Firstly, this paper outlines the development of tufting technology and the structural characteristics of tufted composite materials. Secondly, it reviews existing research on forming tufted preform with curved mold, focusing on three aspects: formability analysis, definition of forming defects, and digital characterization methods. It points out the progress made in current research and the shortcomings that still exist. Furthermore, it summarizes the numerical simulation methods for the forming process of tufted preform, highlighting the specific forming model of the tufted preform. Finally, it explores the future direction of tufting technology in the field of forming for composite materials.
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Key words:
- Tufting /
- 3D preform /
- composite material /
- forming /
- numerical simulation /
- curved surface
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图 3 Tufting缝合设备:(a)英国克兰菲尔德大学KSL KL150 Tufting缝合机头[40]; (b)英国克兰菲尔德大学KSL RS522 Tufting缝合机头[16];(c)天津工业大学自研Tufting样机[45];(d)扬州大学自研Tufting缝合样机
Figure 3. Tufting machines: (a) KSL KL150 Tufting head in Cranfield University[40]; (b) KSL RS522 Tufting head in Cranfield University [16]; (c) Tufting equipment developed by Tiangong University[45]; (d)Tufting equipment developed by Yangzhou University
图 5 记忆合金Tufting缝合T型复合材料结构件:(a)测试后显示镍钛合金Tufting缝合的T型接头断裂的侧视照片;(b)翼缘部分的镍钛合金Tufting缝合线的变形和拉出破坏;(c)镍钛合金Tufting缝合线拉出和断裂扫描电子显微镜图像[57]
Figure 5. Composite T-joints using shape memory alloy tufts: (a) Side-view photograph of fractured T-joint following testing showing bridging and fracture of SMA tufts along the skin-flange interfaces; (b) Large-scale deformation and pull-out failure of SMA tufts along the skinflange section; (c) Scanning electron microscope image of pull-out and fracture of a SMA tuft[57]
表 1 基准样件实验常用凸模形状
Table 1. Common punch geometries for benchmark forming experiments
Punch Geometry Hemisphere Double domes Tetrahedron Prism Square-box Cylinder Schematic Number of edges 0 0 3 4 8 1 Number of triple points 0 0 1 2 4 0 Terminology Definition Schematic Out-of-plane defects Wrinkles When the fabric deforms out-of-plane taking the shape of a waved curve that can vary in length, number and magnitude Folds When the fabric deforms in an out-of-plane curved form, identical to the "wrinkles" mechanism described, the two sides of the curves will fall, one on the other, multiplying the thickness of the fabric locally Buckles When the shifting of the fiber position out-of-plane is randomly creating an irregular yarns pattern distribution Bridging When forming a curved concave form, the material retreats in a corner and the fabric is no longer in contact with the shaping form and stay suspended mid-air In-plane defects Yarn sliding The yarns slides from its initial position to another following its longitudinal or perpendicular direction Yarn misalignment When the yarns are curved locally in plane, and the
yarns are unparallelYarn rupture By applying high tensile stress on the yarn, higher than its maximum resistant stress, it will break the fiber Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Tufting pattern Wrinkles Photos of samples Wrinkle ratio 27.6% 37.4% 20.3% 25.4% 32.1% 表 4 连续纤维复合材料预制体成形过程数值仿真方法
Table 4. Numerical simulation method of continuous fiber composite preform during the forming process
Preform structures Modeling scales Constitutive laws Finite element types Features 3D woven
preformsMacroscopic Hyperelastic Specific shell[94–97] For predicting the transverse shear deformations in the thickness direction during the forming of 3D woven preforms Hypoelastic Mesoscopic Hyperelastic Solid+inter-yarn contact (penalty method)[98-99] For predicting yarn deformation and its defects during the forming of 3D woven preforms Hypoelastic Macroscopic + Mesoscopic Hyperelastic Solid [100] More efficient calculation compared to complete mesoscopic methods Microscopic Elastic Rod+inter-fibers contact algorithm (penalty method) [101] For predicting the deformation behavior of fibers during the weaving process of 3D woven preforms Stithed preforms Macroscopic + Mesoscopic (1) Fabrics:hyperelastic
(2) Stitching thread:elastcShell+Rod+inter-layer contact algorithm+fabric-thread contact algorithm [36-37] For predicting macroscopic forming defects such as wrinkles, which can only describe stitching connection between two layers of fabric because the stitching thread is represented by a single 1D rod NCF
(Non-crimp fabric)Mesoscopic Fabric yarns and stitching thread:non-linear elastic Solid+Rod/Beam+yarn-thread contact algorithm [102-103] For predicting the gapping defects due to yarn slippage during forming of NCF Macroscopic + Mesoscopic (1) Fabrics:hyperelastic
(2) Stitching thread:elastcShell+Rod+inter-layer contact algorithm+ specific fabric-thread contact algorithm (Friction thresold method) [78, 83] For predicting macroscopic forming defects such as wrinkles Macroscopic (1) Shear and tensile deformation of fabrics:elastic-plastic;
(2) In-plane transverse compression of fabrics:non-linear elasticShell [104] For predicting the gapping defects due to yarn slippage and the wrinkling defects during forming of NCF Tufted preforms Macroscopic + Mesoscopic (1) Fabrics:hyperelastic
(2) Tufting thread:elasticShell+Rod+inter-layer contact algorithm+ specific fabric-thread contact algorithm (Sliding thread method)[38] Breaks the ply limit of the models for stitching and NCF, for predicting the wrinkling defects during forming -
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