Ablation-resistant fairing with variable thickness, manufacturing method and fairing forming device

Abstract

The present application relates to the technical field of composite forming methods, and particularly relates to a special-shaped variable-thickness ablation-resistant fairing, a manufacturing method thereof and a fairing forming device, the fairing forming device comprises a metal mold and a sand mold, the metal mold comprises a top plate, a bottom plate, a core barrel and an outer mold; the manufacturing method of the special-shaped variable-thickness ablation-resistant fairing comprises the following steps: manufacturing the fairing forming device, preparing a prepreg containing a base material and a reinforcing material, assembling the forming device and laying the prepreg, heating the product and the forming device as a whole and then performing hot compaction, heating and curing using a high-temperature curing furnace to obtain the special-shaped variable-thickness ablation-resistant fairing. The present application can simplify the forming process, facilitate operation, improve efficiency, improve the internal quality of the product, solve the problem of internal porosity of the product, and solve the problem of difficult post-processing of the product sealing groove through optimization of the design of the forming device.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material forming methods, in particular to a special-shaped variable-thickness ablation-resistant fairing and a manufacturing method and a fairing forming device thereof. BACKGROUND

[0002] In recent years, due to the excellent performance of composite materials, the development of composite materials is rapid, and the aerospace industry, high-speed rail industry and other industrial fields have carried out in-depth research on composite materials. The fairing of the composite material part is mainly used in the engine exhaust jet of the launch vehicle, missile and the like, and its main features are high strength and ablation resistance. However, with the continuous development of the field of composite materials and the increasing requirements, the fairing structure is complex, and the volatile components are high, the forming is difficult, the porosity of the formed product is large, and it is difficult to meet the use requirements of the fairing. SUMMARY

[0003] The purpose of the present application is to overcome the defects of the prior art, provide a special-shaped variable-thickness ablation-resistant fairing and a manufacturing method and a fairing forming device thereof, which can simplify the forming process, facilitate operation, improve efficiency, improve the internal quality of the product, solve the problem of internal porosity of the product, and solve the problem of difficult machining of the product sealing groove in the later stage by optimizing the design of the forming device.

[0004] To achieve the above-mentioned purpose, the following specific technical solutions are adopted in the present application:

[0005] The special-shaped variable-thickness ablation-resistant fairing forming device provided by the present application comprises a metal mold and a sand mold, the metal mold comprises a top plate, a bottom plate, a core barrel and an outer mold, the sand mold is a sand block, the core barrel and the bottom plate are connected through a limiting groove, a positioning pin and a bolt, the core barrel is provided with a limiting groove at the top, the sand mold is embedded in the limiting groove and fixed with the core barrel by using adhesive, and the outer mold and the top plate are connected with the bottom plate, the core barrel and the sand block through bolts.

[0006] The manufacturing method of the special-shaped variable-thickness ablation-resistant fairing provided by the present application comprises the following steps:

[0007] S1, making a special-shaped variable-thickness ablation-resistant fairing forming device;

[0008] S2, preparing a prepreg comprising a base material and a reinforcing material;

[0009] S3, using a numerical control cutting machine to cut the prepreg with a corresponding shape and size;

[0010] S4, assembling the forming device and laying the cut prepreg;

[0011] S5, using a metal mold for normal temperature mold pre-compaction;

[0012] S6, heating and compacting the whole forming device after heating;

[0013] S7, heating and curing the prepreg using a high-temperature curing furnace;

[0014] S8, removing the metal mold and the sand mold to obtain the special-shaped variable-thickness ablation-resistant fairing.

[0015] Further, the base material is selected as barium phenolic resin, the reinforcing material is selected as high-silica glass cloth, and the high-silica barium phenolic prepreg is prepared by using a hot-melt prepreg preparation process in the laying-up forming process.

[0016] Further, the forming device is assembled and the cutting prepreg is laid up, including the following steps:

[0017] S41, assembling and fixing the bottom plate, the core barrel and the sand block in the fairing forming device;

[0018] S42, uniformly applying release agent on the surface of the fairing forming device;

[0019] S43, laying up using the cutting prepreg.

[0020] Further, the cutting prepreg is laid up, including the following steps:

[0021] S431, positioning and bonding the sand mold on the core barrel of the metal mold using structural adhesive;

[0022] S432, laying up using sample material, and heating and vacuumizing and compacting after laying up 4-8 layers.

[0023] Further, the heating and compacting the whole forming device after heating includes the following steps:

[0024] S61, heating the product and the whole forming device in the high-temperature curing furnace using 110-140 DEG C;

[0025] S62, after the temperature of the forming device reaches 110 DEG C ± 20 DEG C, the bolt is pressurized to close the mold, the excess glue is squeezed out, and all the internal volatile molecules are discharged.

[0026] Further, the process conditions for heating and curing the forming device using the high-temperature curing furnace are as follows: the curing temperature is 100-160 DEG C, and the curing time is 5-8 h.

[0027] The special-shaped variable-thickness ablation-resistant fairing is manufactured by the manufacturing method of the special-shaped variable-thickness ablation-resistant fairing.

[0028] The present application can achieve the following technical effects:

[0029] The forming device is designed in the form of combination of the metal mold and the sand mold, facilitates product demolding and forming, sample material is used for laying, mold closing and compaction are carried out after laying is finished, and finally curing is carried out. The forming device simplifies machining process and reduces machining difficulty, the forming process method is low in difficulty and high in efficiency, the obtained product is good in internal quality, and can meet high strength and ablation resistance requirements. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 It is a structure schematic view of a flow guide cylinder forming device provided according to an embodiment of the present application.

[0031] Figure 2 It is an outline schematic view of a special-shaped variable-thickness ablation-resistant flow guide cylinder manufactured by a manufacturing method.

[0032] The reference signs in the drawings include:

[0033] A top plate 1, a bottom plate 2, a core cylinder 3, an outer mold 4 and a sand mold block 5. DETAILED DESCRIPTION

[0034] Hereinafter, embodiments of the present application will be described with reference to the accompanying drawings. In the following description, the same modules are denoted by the same reference signs. In the case of the same reference signs, their names and functions are also the same. Therefore, detailed descriptions thereof will not be repeated.

[0035] In order to make the objectives, technical solutions and advantages of the present application clearer, further detailed descriptions will be made to the present application in combination with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application, and do not constitute limitation to the present application.

[0036] Figure 1 A structure of a flow guide cylinder forming device provided according to an embodiment of the present application is shown, which includes a metal mold and a sand mold. The metal mold includes a top plate, a bottom plate, a core cylinder and an outer mold, and the sand mold is a sand mold block.

[0037] The forming device is designed in the form of combination of the metal mold and the sand mold, facilitates product demolding and forming, and simultaneously simplifies machining process and reduces machining difficulty.

[0038] The present application provides a manufacturing method of a special-shaped variable-thickness ablation-resistant flow guide cylinder, which includes the following steps.

[0039] S1, a flow guide cylinder forming device is manufactured.

[0040] S2, a prepreg containing a matrix material and a reinforcing material is prepared.

[0041] The base material is selected as barium phenolic resin, the reinforcing material is selected as high-silica glass cloth, and the high-silica barium phenolic prepreg cloth is prepared by using a hot-melt prepreg process in the lay-up forming process.

[0042] S3, cutting the prepreg cloth with a corresponding shape and size using a numerical control cutting machine.

[0043] S4, assembling the forming device and laying up the cut prepreg cloth.

[0044] Assembling the forming device and laying up the cut prepreg cloth includes the following steps:

[0045] S41, assembling and fixing the bottom plate, core barrel and sand mold block in the flow guide barrel forming device;

[0046] S42, uniformly applying release agent on the surface of the flow guide barrel forming device;

[0047] S43, laying up the cut prepreg cloth.

[0048] Laying up the cut prepreg cloth includes the following steps:

[0049] S431, positioning and bonding the sand mold mold on the core barrel of the metal mold using structural adhesive;

[0050] S432, laying up using sample material, and heating and vacuumizing and compacting after laying up 4-8 layers.

[0051] S5, using a metal mold to pre-compact at room temperature.

[0052] S6, heating the entire forming device and then hot compacting.

[0053] Heating the entire forming device and then hot compacting includes the following steps:

[0054] S61, heating the product and the entire forming device in a high-temperature curing oven at 110-140°C;

[0055] S62, after the temperature of the forming device reaches 110±20°C, screw bolt pressurization is performed to compact the mold, excess glue is squeezed out, and all internal volatile molecules are discharged.

[0056] S7, heating and curing the forming device using a high-temperature curing oven.

[0057] The process conditions for heating and curing the forming device using a high-temperature curing oven are: curing temperature 100-160°C, and total curing time 5-8h.

[0058] S8, removing the metal mold and cleaning the sand mold mold to obtain a special-shaped thickened ablation-resistant flow guide barrel.

[0059] The manufacturing method provided by the application has low difficulty and high efficiency, and the obtained product has good internal quality and can meet the requirements of high strength and ablation resistance.

[0060] Figure 2 The shape of the ablation-resistant fairing with variable thickness manufactured by the manufacturing method provided by the embodiment of the application is shown.

[0061] In the description of the specification, the description of the terms "one embodiment", "some embodiments", "an example", "a specific example", or "some examples" means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the application. In the specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples. In addition, the person skilled in the art can combine and combine the different embodiments or examples described in the specification and the features of the different embodiments or examples without contradiction.

[0062] Although the embodiments of the application have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting the application, and those skilled in the art can make changes, modifications, replacements and variations to the above embodiments within the scope of the application.

[0063] The specific embodiments of the application described above do not constitute a limitation on the scope of protection of the application. Any various other corresponding changes and modifications made according to the technical concept of the application shall be included in the scope of protection of the claims of the application.

Claims

1. A forming device for an irregularly shaped, variable-thickness, ablation-resistant guide tube, characterized in that, The system includes a metal mold and a sand mold. The metal mold includes a top plate, a bottom plate, a core cylinder, and an outer mold. The sand mold is a sand block. The core cylinder is connected to the bottom plate by a limiting groove, a positioning pin, and bolts. A limiting groove is provided at the top of the core cylinder. The sand mold is embedded in the limiting groove and fixed to the core cylinder. The outer mold and the top plate are connected to the bottom plate, the core cylinder, and the sand block by bolts, forming a closed mold cavity for hot pressing.

2. A method for manufacturing an irregularly shaped, variable-thickness, ablation-resistant guide tube, characterized in that, Includes the following steps: S1. Fabricate the irregularly shaped, variable-thickness, ablation-resistant guide tube forming device as described in claim 1; S2. Prepare a prepreg containing a matrix material and a reinforcing material; the matrix material is barium phenolic resin, and the reinforcing material is high silica glass cloth. The high silica barium phenolic prepreg is prepared by hot melt prepreg preparation process and then laid out and shaped. S3. Use a CNC cutting machine to cut prepreg fabric to the corresponding shape and size; S4. Assemble the molding device and lay it out using the cut prepreg fabric. S5. Use the metal mold to perform room temperature mold closing and pre-compacting; S6. The molding device is heated as a whole and then hot-pressed; including the following steps: S61. The product and molding device are heated together in a high-temperature curing oven at 110℃-140℃; S62. After the temperature of the molding device reaches 110℃±20℃, the bolts are used to pressurize and close the mold, squeezing out the excess adhesive and expelling all the small volatile molecules inside. S7. The prepreg fabric is heated and cured using a high-temperature curing oven; S8. Remove the metal mold and clean the sand mold to obtain the irregularly shaped, thickened, ablation-resistant guide tube.

3. The manufacturing method of the irregularly shaped, variable-thickness, ablation-resistant guide tube according to claim 2, characterized in that, In step S4, the assembly and molding device is laid out using the pre-cut prepreg fabric, which includes the following steps: S41. Assemble and fix the bottom plate, core cylinder and sand mold block in the guide tube forming device; S42. Apply release agent evenly to the surface of the guide tube forming device; S43. Lay out the pre-prepared fabric using the cut-out fabric.

4. The manufacturing method of the irregularly shaped, variable-thickness, ablation-resistant guide tube according to claim 3, characterized in that, In step S43, laying out the pre-cut prepreg fabric includes the following steps: S431. The sand mold is positioned and bonded to the core of the metal mold using structural adhesive; S432. Use sample material for laying, and heat and vacuum compact after every 4-8 layers.

5. The manufacturing method of the irregularly shaped, variable-thickness, ablation-resistant guide tube according to claim 2, characterized in that, In step S7, the process conditions for heating and curing the molding device using a high-temperature curing oven are: curing temperature 100℃~160℃, curing time 5-8h.

6. A variable thickness ablation resistant guide tube, characterized in that, It is manufactured by the method described in any one of claims 2-5.

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