某大型飞机复合材料壁板工艺仿真及验证技术

Simulation and verification technique for composite parts for some large civil aircraft

热压罐固化成型是制造复合材料的常用方法,固化期间罐内温度分布变化以及模具与复合材料构件之间的热不匹配、柔性模具的低热导率等因素导致制件内部不可避免的产生温度梯度以及残余应力,从而影响材料的使用性能。大尺寸曲面帽型壁板采用复合材料热压罐工艺成型,根据热压罐的工作原理,针对复合材料构件热压罐成型过程中温度场分布和固化变形等问题,进行了仿真分析,通过对比制件温度场分布和固化变形仿真计算结果以及全尺寸零件的实际验证结果,验证了预测方法的正确性。分别利用成型工装和检测型架改进优化以及制造过程优化来控制构件固化变形,使其形状满足产品尺寸的精度要求,证明根据工艺仿真计算结果以及工艺过程改进,可以对大尺寸曲面帽型壁板在制造工艺过程中出现的变形回弹及残余应力水平进行预估和最大限度的减小,实现复合材料结构设计和制造的一体化,提高制件的成型质量。

Autoclave process is commonly used for composites manufacture.During this process,factors including the temperature distribution changes in the tank,the thermal coefficients mismatch between the mold and composite components,and the low thermal conductivity of flexibility mold result in the inevitable generation of temperature gradient and the residual stress in the parts,thus affecting the performance of the materials.Composite large-scale hyperboloid hat-stiffened panels adopt autoclave process as well.According to the working principle of autoclave,the temperature field distribution and curing deformation in the process of the autoclave molding were simulated and analyzed.By comparing the simulation results and the actual results of the full-size parts,the validity of the simulation was verified,and the dimensional precision of the product was satisfied by optimization of the manufacturing process and the inspection method of mold quality to control curing deformation.The results for the simulation and the optimization of manufacturing process show that the deformation resilience and the residual stress of the composite large-scale hyperboloid hat-stiffened panels during formation process could be predicted and eliminated at the utmost,which is beneficial to integrate the design and manufacture process as well as improve the forming quality of the parts.