A forming method and application of a large-scale bidirectional variable-curvature framework detachable core mold

Abstract

A forming method and application of a large-scale bidirectional variable-curvature framework detachable core mold, which adopts a large-scale bidirectional variable-curvature framework, fully identifies the outer surface line type of the large-scale bidirectional variable-curvature framework, decomposes the outer surface of the large-scale bidirectional variable-curvature framework into several decomposition regions, then produces embedded clamping plates according to the outer surface line type of each region, and embeds and fixes the embedded clamping plates on the corresponding positions of the framework, constructs a grid-shaped outer surface lining of the framework, then fills the framework with foaming foam, only needs to polish the foam to expose the embedded clamping plates, and polish the foam between adjacent embedded clamping plates to smooth transition, so as to realize a high-precision core mold forming basically consistent with the outer surface type value of the framework, then inspects the line type precision of the core mold, and corrects the line type of individual line type out-of-tolerance positions, and finally completes the high-precision filling forming of the large-scale bidirectional variable-curvature framework detachable core mold.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of composite material removable core mold forming, in particular to a forming method and application of a large-scale bidirectional variable curvature framework removable core mold. BACKGROUND

[0002] Fiber reinforced resin matrix composite (hereinafter referred to as composite material) is gradually widely used in shipbuilding, aviation, transportation and other industrial fields due to its high strength, high stiffness, light weight, good environmental performance and diverse functional characteristics. In the field of shipbuilding and ocean engineering, composite material components often have the characteristics of super large size, integral forming with framework, complex surface line type and high line type precision requirement. The forming method of such composite material components is mainly to fill the framework with foaming foam and other materials, and then to construct a mold surface with the framework and the filling foam, and then to form the composite material and the framework integrally on the mold surface. After the composite material component is formed, the filling foam is removed.

[0003] For such composite material components formed by relying on the removable core mold of the framework, the line type precision of the core mold directly determines the line type precision of the component, and the control difficulty of the line type precision of the core mold has two aspects: ① the size of the composite material component is super large; ② the surface line type is extremely complex, and the local line type is bidirectional variable curvature. Due to the super large size of the composite material component, the surface line type precision of the core mold cannot be processed and controlled by numerical control machining means. At present, the core mold line type control is mainly achieved by manual polishing and shaping. However, due to the lack of effective operation guidance, manual polishing needs to be repeatedly inspected and shaped, which is extremely low in efficiency, consumes a large amount of labor, and is difficult to effectively control the line type precision of the core mold, so as to ensure the line type precision of the composite material component. SUMMARY

[0004] Therefore, the present application aims to provide a filling forming method and application of a large-scale bidirectional variable curvature framework removable core mold, so as to solve the problem that the surface line type precision of the core mold cannot be processed and controlled by numerical control machining means due to the super large size of the composite material component, and the core mold line type control is mainly achieved by manual polishing and shaping at present. However, due to the lack of effective operation guidance, manual polishing needs to be repeatedly inspected and shaped, which is extremely low in efficiency, consumes a large amount of labor, and is difficult to effectively control the line type precision of the core mold, so as to ensure the line type precision of the composite material component.

[0005] To achieve the above purpose, the technical scheme of the present application is as follows:

[0006] A forming method of a large-scale bidirectional variable curvature framework removable core mold, which adopts a large-scale bidirectional variable curvature framework, and includes the following steps:

[0007] Step one, the outer shape line of the large-scale two-way variable curvature skeleton is fully identified, and the outer shape surface of the large-scale two-way variable curvature skeleton is divided into several decomposition regions;

[0008] Step two, the embedding style of the embedded card plate is determined according to the curvature change characteristics of the outer shape surface of each decomposition region, wherein the outer leakage side of the embedded card plate is co-shaped with the skeleton;

[0009] Step three, the embedded card plate is embedded and fixed on the skeleton, and the embedded card plate constructs a grid-shaped skeleton outer shape surface lining on the skeleton, and the skeleton outer shape surface lining is provided with a filling area;

[0010] Step four, the filling area in the skeleton is filled with foam material;

[0011] Step five, the filled foam material is polished to expose the embedded card plate, and the filling foam between any adjacent embedded card plates is polished to smooth transition to form a core mold;

[0012] Step six, the performance of the core mold obtained in step five is tested.

[0013] The setting provides a large-scale two-way variable curvature skeleton detachable core mold high-precision filling forming method, which is a large-scale complex linear skeleton detachable core mold high-precision manufacturing method with strong operability and high efficiency, and provides reliable technical support for the complex linear high-precision control of the large-scale two-way variable curvature composite material shell plate formed by the detachable core mold outer shape surface.

[0014] Further, the size of the decomposition region is ≤1000mm*600mm.

[0015] Further, the embedded card plate is a steel strip-shaped sheet with a thickness of 3-5mm, a width of 30-50mm, and a length of 300-1000mm.

[0016] The setting can ensure the rigidity of the embedded card plate, so that the embedded card plate is not easy to deform.

[0017] Further, the positioning accuracy of the embedded card plate is ±0.5mm.

[0018] The setting can improve the linear precision of the core mold, thereby ensuring the linear precision of the composite material component formed by relying on the detachable core mold of the skeleton, and has a broad application prospect in the fields of ships and ocean engineering.

[0019] Further, in step four, the density of the filling foam is ≥150kg / m 3 , and the height of the filling foam is ≥200mm.

[0020] The setting can fill the skeleton to form a core mold structure.

[0021] Further, the performance test of the core mold includes the test of linear precision, and the test standard of the linear precision of the core mold is ±1mm.

[0022] The setting can ensure the linear precision of the composite material component formed by the detachable core mold relying on the skeleton, so that the core mold has a wide application prospect in the fields of ships and ocean engineering.

[0023] Further, in the sixth step, the performance test of the core mold includes the test of air tightness, and the test standard of the air tightness test is that the test starts at an extreme vacuum degree ≥0.095 MPa, the vacuum is closed, the waiting time is 5 minutes, and the vacuum degree is ≥0.080 MPa.

[0024] Further, in the sixth step, the performance test of the core mold also includes the test of pressure bearing capacity, and the test standard of the pressure bearing capacity is that the core mold does not collapse after 12 hours of test under the pressure of the extreme vacuum degree.

[0025] Further, the embedded card plate is fixed on the skeleton in a spot welding mode.

[0026] The setting is beneficial to the dismounting and mounting of the embedded card plate and the skeleton.

[0027] An application of a forming method, which uses the forming method of the large-scale bidirectional variable-curvature skeleton detachable core mold.

[0028] Compared with the prior art, the forming method of the large-scale bidirectional variable-curvature skeleton detachable core mold and the application have the following advantages:

[0029] 1. The large-scale bidirectional variable-curvature skeleton detachable core mold linear precision control polishing operation method proposed by the application has traceability and is targeted, and has strong engineering operability.

[0030] 2. The large-scale bidirectional variable-curvature skeleton detachable core mold filling forming method proposed by the application does not need to repeatedly perform core mold linear test and modification, is high in efficiency, can greatly save manpower and material resources, and reduces manufacturing cost.

[0031] 3. In the application, the linear precision of the core mold is ±1mm, the linear high-precision control of the large-scale bidirectional variable-curvature skeleton detachable core mold is realized, the linear precision of the composite material component formed by the detachable core mold relying on the skeleton is ensured, and the application prospect in the fields of ships and ocean engineering is wide. DETAILED DESCRIPTION

[0032] Figure 1 Front view of large-scale bidirectional variable curvature framework of the present application;

[0033] Figure 2 First longitudinal rib right side view of large-scale bidirectional variable curvature framework of the present application;

[0034] Figure 3 Second longitudinal rib right side view of large-scale bidirectional variable curvature framework of the present application

[0035] Figure 4 Third longitudinal rib right side view of large-scale bidirectional variable curvature framework of the present application;

[0036] Figure 5 Structure diagram of setting embedded clamping plate in the decomposition area of large-scale bidirectional variable curvature framework of the present application.

[0037] Explanation of reference signs:

[0038] 1-first longitudinal rib, 2-second longitudinal rib, 3-third longitudinal rib, 4-first transverse rib, 5-second transverse rib, 6-embedded clamping plate, 7-filling area, A-first area, B-second area. DETAILED DESCRIPTION

[0039] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings.

[0040] The present application relates to a filling forming method of large-scale bidirectional variable curvature framework detachable core mold, which adopts large-scale bidirectional variable curvature framework, and includes the following steps:

[0041] Step one, fully identify the outer surface line type of large-scale bidirectional variable curvature framework, and decompose the outer surface of large-scale bidirectional variable curvature framework into several decomposition areas; the decomposition into several decomposition areas can be understood as decomposition into areas with smaller size, more single curvature change direction and approximate range of curvature;

[0042] Step two, determine the embedded style of embedded clamping plate according to the curvature change characteristics of each decomposition area outer surface, wherein the outer leakage side of the embedded clamping plate is co-molded with the framework; the style of the embedded clamping plate includes bidirectional formation and unidirectional formation, wherein for the area with large bidirectional curvature change, the embedded clamping plate is designed as a relatively dense bidirectional form with cross clamping plates inserted, and for the area with large unidirectional curvature change, the embedded clamping plate is designed as a relatively sparse unidirectional form;

[0043] Step three, embed and fix the embedded clamping plate on the framework, the embedded clamping plate constructs a grid-shaped framework outer surface lining on the framework, and the framework outer surface lining is provided with a filling area;

[0044] Step four, filling the filling area in the framework with foam material;

[0045] Step five, polishing the filled foam material to expose the embedded card board, and polishing the filling foam between any adjacent embedded card boards to smooth transition to form a core mold;

[0046] Step six, test the line type accuracy, air tightness and pressure bearing capacity of the core mold.

[0047] The setting provides a large-scale two-way variable curvature framework detachable core mold high-precision filling forming method, which is a high-efficiency large-scale complex linear framework detachable core mold high-precision manufacturing method with strong operability, and provides reliable technical support for large-scale two-way variable curvature composite material shell complex linear high-precision control relying on the outer shape forming of the detachable core mold.

[0048] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the embodiments of the present application.

[0049] The present application relates to a large-scale two-way variable curvature framework detachable core mold, which comprises a large-scale two-way variable curvature linear composite material component local framework structure as shown in the figure, Figures 1-4 Two decomposition areas are arranged in the framework, and embedded card boards 6 are arranged in the decomposition areas as shown in the figure. Figure 5

[0050] Specifically, the framework is formed by a first longitudinal rib 1, a second longitudinal rib 2, a third longitudinal rib 3, a first transverse rib 4 and a second transverse rib 5.

[0051] Specifically, the second longitudinal rib 2 is located between the first longitudinal rib 1 and the third longitudinal rib 3.

[0052] Specifically, the framework forms a first area A and a second area B, that is, the first longitudinal rib and the second longitudinal rib form the second area with the first transverse rib and the second transverse rib, and the second longitudinal rib and the third longitudinal rib form the first area with the first transverse rib and the second transverse rib, and the curvature change of the first area is greater than that of the second area.

[0053] Specifically, the embedded card board in the first area is arranged in a mesh structure with longitudinal and transverse interfitting, and the embedded card board arranged in the second area is arranged in a longitudinal structure.

[0054] Specifically, the embedded card board is internally provided with a filling area 7, the filling area can be filled with foam, and the filling area varies according to the style of the embedded card board.

[0055] A large-scale two-way variable curvature framework detachable core mold high-precision filling forming method is adopted, and the above-mentioned large-scale two-way variable curvature framework is adopted, comprising the following steps:​

[0056] Step 1: Fully identify the surface lines of the large-scale bidirectional variable curvature skeleton. Decompose the surface of the large-scale bidirectional variable curvature skeleton into smaller regions with relatively simple curvature change directions and curvature within an approximate range. In the first region A, the upper skeleton surface has large curvature changes in both the horizontal and vertical directions, while the lower skeleton surface is planar. In the second region B, the upper skeleton surface has large vertical curvature changes and small horizontal curvature changes, while the lower skeleton surface is planar. The skeleton surfaces of all regions other than the first and second regions are planar or approximately planar.

[0057] Step 2: Design and fabricate longitudinal and transverse embedded clamps based on the linear characteristics of the external surfaces of each decomposed region. The embedded clamps are thin steel strips with exposed sides conforming to the frame. The machining accuracy is ±0.5mm. For regions A and B, where the upper frame surface curvature is complex, embedded clamps are designed only for these regions. Figure 5 As shown. In the first region A, the curvature of the upper skeleton surface changes significantly in both the horizontal and vertical directions; therefore, the embedded card plates are designed in a relatively dense, bidirectional, intersecting pattern. In the second region B, the curvature of the upper skeleton surface changes significantly in the vertical direction but less in the horizontal direction; therefore, the embedded card plates are designed in a relatively sparse, longitudinal pattern. The embedded card plates are 5mm thick, 40mm wide, and 600–800mm long, with a spacing of 50–200mm between embedded card plates in a single direction.

[0058] Step 3: The embedded card plate is embedded and fixed in the corresponding position of the skeleton by spot welding. The positioning accuracy of the embedded card plate is ±0.5mm. A grid-like skeleton outer surface lining is constructed on the skeleton, and the skeleton outer surface lining is provided with a filling area.

[0059] Step 4: Fill the inner lining area of ​​the skeleton's outer surface with foam or similar materials, ensuring the foam density is ≥150kg / m³. 3 The filling height is ≥200mm;

[0060] Step 5: Polish the foam to expose the embedded card plate, and polish the foam between adjacent embedded card plates to achieve a smooth transition. This will enable the core mold to be formed with high precision, which basically conforms to the shape value of the skeleton.

[0061] Step 6: Inspect the accuracy, airtightness and pressure bearing capacity of the mandrel, and correct any deviations in the mandrel's shape. The accuracy of the mandrel's shape is ±1mm, the ultimate vacuum degree of the mandrel is ≥0.095MPa, the vacuum degree is ≥0.080MPa 5min after the vacuum is closed, and the mandrel does not collapse after 12h under the ultimate vacuum pressure.

[0062] The setting proves that the core mold structure prepared by the molding method has good strength and high quality.

[0063] The high-precision filling molding method of the large-scale bidirectional variable-curvature skeleton detachable core mold in the application can control the core mold line type with high precision, and the obtained core mold has high quality and meets the quality requirements of the core mold, thereby ensuring the line type precision of the composite material component formed by the core mold relying on the skeleton, and having wide application prospects in the fields of ships and ocean engineering.

[0064] Although the application is disclosed as above, the application is not limited to this. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the application, and the protection scope of the application should be subject to the scope defined by the claims.

Claims

1. A forming method of a large-scale bidirectional variable curvature skeleton detachable core mold using a large-scale bidirectional variable curvature skeleton, characterized by, The method comprises the following steps: Step one, fully identify the outer surface line type of the large-scale two-way variable curvature skeleton, and decompose the outer surface of the large-scale two-way variable curvature skeleton into several decomposition regions; Step two, determine the embedded style of the embedded card according to the curvature variation characteristics of the outer surface of each decomposition region, wherein the outer leakage side of the embedded card is co-surfaced with the skeleton; Step three, embed and fix the embedded card on the skeleton, the embedded card constructs a grid-shaped skeleton outer surface lining on the skeleton, and the skeleton outer surface lining is provided with a filling area; Step four, fill the filling area in the skeleton with foam material; Step five, polish the filled foam material, so that the embedded card is exposed, and the filling foam between any adjacent embedded cards is polished to smooth transition to form a core mold; Step six, perform core mold performance test on the core mold obtained in step five.

2. The forming method of a large-scale bidirectional variable-curvature framework detachable plug mold according to claim 1, characterized in that, The size of the decomposition region is ≤1000mm*600mm.

3. The molding method for a large-scale bidirectional variable curvature skeleton detachable core mold according to claim 1, characterized in that, The embedded card is a steel strip-shaped sheet with a thickness of 3-5mm, a width of 30-50mm, and a length of 300-1000mm.

4. The method of claim 1, wherein the large-scale bidirectional variable curvature framework core mold is formed by the steps of: The positioning accuracy of the embedded card is ±0.5mm.

5. The method of claim 1, wherein the large scale bidirectional variable curvature framework core is removable. The density of the filled foam is ≥ 150 kg / m3 3 The height of the filled foam is ≥ 200 mm.

6. The method of claim 1, wherein the large scale bidirectional variable curvature framework core is removable. In step six, the performance test of the core mold includes linear accuracy test, and the linear accuracy test standard of the core mold is ±1mm.

7. The method of claim 1, wherein the large scale bidirectional variable curvature framework core is removable. In step six, the performance test of the core mold includes air tightness test, and the air tightness test standard is that the test starts at an extreme vacuum degree of ≥0.095MPa, the vacuum is closed, the waiting time is 5min, and the vacuum degree is ≥0.080MPa.

8. The molding method for a large-scale bidirectional variable curvature skeleton detachable core mold according to claim 1, characterized in that, In step six, the core mold performance test also includes pressure bearing capacity test, and the pressure bearing capacity test standard is that the core mold does not collapse after 12h of test time under the extreme vacuum degree pressure.

9. The method of claim 1, wherein the method further comprises the step of: The embedded card is fixed on the skeleton by spot welding.

10. Use of a forming method, characterized in that, The forming method of the large-scale two-way variable curvature skeleton detachable core mold of any one of claims 1-9 is applied to the forming and manufacturing of the detachable core mold and the composite material.

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