Tufting复合材料预制体成形及数值仿真研究进展

申皓; 玛日耶姆·阿卜力米提; 李志辉; 祁欣; 黄晋

Tufting复合材料预制体成形及数值仿真研究进展

1.
扬州大学　机械工程学院, 扬州 225127
2.
北京流体动力科学研究中心, 北京100011

基金项目: 国家自然科学基金 (12202467)；江苏省自然科学基金(BK20220597)

详细信息

通讯作者:
黄晋，博士，助理研究员，研究方向为复合材料结构与力学、热防护复合材料性能　E-mail: huangjin312@126.com

中图分类号: TB332
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- 文章访问数: 137
- HTML全文浏览量: 76
- 被引次数: 0
出版历程
- 收稿日期: 2024-01-30
- 修回日期: 2024-03-29
- 录用日期: 2024-04-05
- 网络出版日期: 2024-05-06

Advances in forming and numerical simulation research of tufted composite preforms

1.
School of Mechanical Engineering, Yangzhou University, Yangzhou 225127, China
2.
Beijing Aerohydrodynamic Frontier Research Center, Beijing 100011, China

Funds: National Natural Science Foundation of China (No. 12202467); Natural Science Foundation of Jiangsu Province (No. BK20220597)

摘要

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。
- Tufting缝合/簇绒缝合 /
- 三维预制体 /
- 复合材料 /
- 成形 /
- 数值仿真 /
- 曲面
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.
- Tufting /
- 3D preform /
- composite material /
- forming /
- numerical simulation /
- curved surface

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图 1 Tufting缝合工艺设备发展历史流程

Figure 1. The development of tufting equipment and process

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图 2 Tufting缝合原理：(a) Tufting缝合工艺流程示意图；(b)对心曲柄滑块机构；(c)偏置曲柄滑块机构

Figure 2. Principle of tufting: (a) Schematic of tufting process; (b) Centric slider-crank mechanism; (c) Off-set slider-crank mechanism

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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

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图 4 Tufting缝合线损伤：(a) Tufting缝合线磨损^[41]；(b) Tufting缝合线断裂^[41]；(c) Tufting缝合线的羽化度表征^[52]

Figure 4. Degradation of tufting thread: (a) Yarn damage^[41]; (b) Yarn rupture^[41]; (c) Characterization of yarn damage^[52]

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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]

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图 6 压边类型及作用：(a) 整体型压边；(b) 离散型压边；(c) 压边对不同方向Tufting缝合线的影响^[14]

Figure 6. Types and effects of blank-holder: (a) Integral blank-holder；(b) Discrete blank-holder；(c) Influence of blank-holder on tufting yarn with different direction^[14]

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图 7 预制体收缩量示意图：(a) 弱约束预制体；(b) 强约束预制体^[39]

Figure 7. Schematic of material draw-in: (a) Preform with weak connection；(b) Preform with strong connection^[39]

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图 8 Tufting缝合图案对预制体收缩量的影响^[33]

Figure 8. Influence of tufting patterns on material draw-in^[33]

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图 9 预制体层间滑移：(a) 层间滑移测量方法^[78]；(b) Tufting缝合对预制体层间滑移的影响^[33]

Figure 9. Interlayer sliding of preform: (a) Interlayer sliding measurement^[78]; (b) Influence of tufting yarn on interlayer sliding^[33]

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图 10 剪切角的测量^[84]

Figure 10. Measurement for shear angle^[84]

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图 11 织物剪切变形对Tufting缝合线的影响^[86]

Figure 11. Influence of fabric shear deformation on tufting yarns^[86]

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图 12 算法示意图：(a) Tufting缝合简化模型，(b) Tufting缝合全结构模型，(c) 滑动绳索接触算法^[38]

Figure 12. Schematics of algorithm: (a) Simplified model of tufting, (b) Full structure model of tufting, (c) Sliding-thread contact algorithm^[38]

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图 13 算法示意图：(a) 接触搜索算法^, (b) Tufting缝合相对滑移模型^[38]

Figure 13. Schematics of algorithm: (a) Detection algorithm of contact (b) Relative sliding model of tufting yarn^[38]

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图 14 Tufting缝合成形实验与仿真对比^[38]

Figure 14. Comparison between the forming experiment and simulation with tufting^[38]

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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

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表 2 成形缺陷^[26]

Table 2. Forming defects^[26]

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 unparallel
Yarn rupture	By applying high tensile stress on the yarn, higher than its maximum resistant stress, it will break the fiber

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表 3 Tufting缝合图案对褶皱缺陷的影响^[34]

Table 3. Effect of tufting pattern on wrinkles^[34]

	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%

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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 preforms	Macroscopic	Hyperelastic	Specific shell^[94–97]	For predicting the transverse shear deformations in the thickness direction during the forming of 3D woven preforms
	Macroscopic	Hypoelastic	Specific shell^[94–97]
	Mesoscopic	Hyperelastic	Solid+inter-yarn contact(penalty method)^[98,99]	For predicting yarn deformation and its defects during the forming of 3D woven preforms
	Mesoscopic	Hypoelastic	Solid+inter-yarn contact(penalty method)^[98,99]
	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：elastc	Shell+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：elastc	Shell+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 elastic	Shell ^[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：elastic	Shell+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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