民用飞机机翼翼尖端部全高度泡沫芯壁板制造技术

Manufacturing technology of full-height foam core panels at the tip of civil aircraft wings

民用飞机机翼翼尖端部组件结构为全高度泡沫夹芯壁板,由“C”形端隔板、尾边条、楔形块、泡沫芯、外蒙皮组成,型面公差要求严,装配关系复杂,制造过程极易引发内部无损与结构变形,对结构制造工艺的可行性与稳定性提出了严重挑战。通过对泡沫胶接质量验证、泡沫芯进行压缩试验验证,验证了胶膜黏接质量可靠性,同时得出泡沫芯厚度的1%作为蠕变压缩的工艺补偿量。采用AIRPAD-碳布叠层压力垫结构形式,使其在高温固化过程中进行膨胀从而有效进行压力均匀传递,保证端隔板零件制造厚度和消除表面皱褶。对外蒙皮加强层、整层、迎风面进行铺层展开可行性分析,对于无法展开区域按平行于纤维方向进行工艺分片,按照规范拼层错缝调整,在满足设计要求下进行剪口处理,从而保证料片外形与产品外形一致性。为控制组件共胶接质量,采用上/下组合模形式,组合模选用复合材料结构上半模,保证其具有随热压预浸料厚度下降而适应性形变的韧性。通过上述研究成功研制符合设计要求的合格产品并进行装机应用。

The component structure of the tip section of the civil aircraft wing is a full-height foam sandwich panel,which consists of"C"-shaped end bulkheads,trailing edge strips,wedge-shaped blocks,foam core and outer skin,with strict profile toler‐ances,complex assembly relationships,and a manufacturing process that is prone to internal non-destructive and structural deformations,which poses a serious challenge to the feasibility and stability of the structural manufacturing process.By verifying the quality of foam bonding and foam core compression test,the reliability of adhesive film bonding quality was verified,and at the same time,1%of the foam core thickness was derived as the process compensation amount for creep compression.The AIRPAD-carbon cloth laminated pressure pad structure was used to allow for expansion during the high temperature curing process,thus effectively trans‐mitting pressure uniformly,guaranteeing the thickness of the end spacer parts and eliminating surface wrinkles.Feasibility analysis of the outer skin reinforcement layer,the whole layer,the windward side of the spreading of the layer to unfold the area cannot be unfolded according to the direction of the fiber parallel to the technology of the slice,in accordance with the specification of the staggered layer of the adjustment of the wrong seam,in order to meet the design requirements for the shear processing,so as to ensure that the shape of the piece of material and the consistency of the shape of the product.In order to control the quality of component co-gluing,the upper/lower combination mold form was adopted,and the upper half mold of composite structure was selected for the combination mold to ensure that it has the toughness of adaptive deformation with the decrease in thickness of hot-pressing prepreg.Through the above research,qualified products have been successfully developed that meet the design requirements and have been installed and applied.