航空复合材料的组合凸轮式Z-pin预植入机的设计与实现

Design and implementation of combination cam-type Z-pin pre-insertion device for aeronautical materials

为解决当前Z-pin植入设备植入效率低、Z-pin易折断或打滑等问题,并推动Z-pin增强技术高效地应用于民用和国防事业,开发了基于组合凸轮的高效高精度Z-pin预植入机。首先,根据航空矩形类复合材料层合构件的预植入工艺技术要求,分析了预植入机的功能需求。其次,提出了先"剪切"后"植入"组合凸轮式预植入机的机构运动方案。采用解析法设计了预植入机的凸轮机构,计算了凸轮机构的理论轮廓曲线。然后,构建了含有间隙凸轮机构的弹性动力学模型,优化了组合凸轮的转速,进行了组合凸轮的虚拟样机运动仿真。最后,设计制造了实验样机,通过植入实验验证了组合凸轮设计的正确性和合理性,并根据实验中出现的问题优化了植入运动方案。实验结果表明,该方案使Z-pin植入效率得到大幅提高,以植入间距3mm×3mm为例,其效率能够达到5 080mm2/min,植入成功率控制在99%以上,植入间距、植入深度和纤维长度等参数的精度均控制在±0.01mm以内。预植入机操作方便,人机界面友好,长时间工作平稳,无Z-pin折断等问题出现,能满足当前对Z-pin植入设备植入效率、植入精度的要求。

In this study,a new high-efficiency and high-precision Z-pin pre-insertion based on a combination cam was developed to solve the problems,such as low efficiency,easy breaking,and slipping of Z-pin insertion.One of the aims is also to promote the application of the Z-pin composite technology in both military and civil fields.First,the functional requirements of the pre-insertion machine were analyzed according to the pre-insertion technology requirements of laminated composite members of the rectangle-type aviation.Second,the mechanism motion scheme of the 'shear after implant'combined cam-type program was proposed for the pre-insertion machine. The cam mechanism of the pre-insertion machine was designed using the analytical method,and the theoretical profile curve of the cam mechanism was deduced.Third,the elastic dynamics model,including the clearance cam mechanism,was constructed.Next,the rotational speed of the combined cam was optimized,and its virtual prototype motion simulation was performed. Subsequently,the experimental prototype was designed and manufactured,and the correctness and rationality of the combined cam design were verified by conducting the implant experiment.The implant motion scheme was optimized according to the problems found in the experiment.The experimental results showed that the scheme could greatly improve the efficiency of the Z-pin implantation.Its efficiency reached5 080 mm2/min,the implantation success rate was controlled above 99%,and the implant parameters such as the implant spacing,implantation depth,and fiber length were controlled within±0.01 mm.Hence,the pre-implanting machine is easy to operate,human-machine interface-friendly,stable in long-term operation,and there are no problems such as Z-pin breaking,which can meet the current requirements of implant efficiency and implantation accuracy of Z-pin implanted devices.