Method for automated manufacturing of composite i-beams

Abstract

The present application belongs to the field of composite material manufacturing, and relates to a kind of composite material beam automation manufacturing method.The present application proposes a kind of disc positioner, with multiple functions, such as automatic laying strip blank on the positioning of corresponding heat diaphragm forming die, forming die, heat diaphragm forming die and forming die combination positioning, composite tooling on the positioning of part blank and so on.In addition, the disc positioner has detachable function, and the conical pin on the protruding surface is detached from the disc positioner after completing the positioning function, so that the disc positioner does not have protruding structure, and then does not affect the heat diaphragm preforming, curing forming and the like, reduces the forming difficulty of preforming and curing forming.The present application discards the common structure layout of designing bushing hole on both sides of a set of heat diaphragm die and designing positioning pin on both sides of another set of die, because the protruding structure design of such bushing hole and positioning pin will seriously affect the diaphragm effect of heat diaphragm, and even easily damage the diaphragm.

Description

Technical Field

[0001] The invention belongs to the field of composite material manufacturing and relates to an automatic manufacturing method of a composite material I-shaped beam. Background Art

[0002] Composite parts are increasingly being used in primary and secondary aircraft load-bearing structures due to their high specific strength, specific modulus, light weight, fatigue resistance, corrosion resistance, flame retardancy, and ease of integral curing and molding. Advanced large aircraft primary load-bearing structures, such as the vertical tail box and center wing box, prioritize composite structural design. As the primary load-bearing components of these sections, composite beams—critical components—demand very high manufacturing precision.

[0003] Currently, there are two primary forming methods for composite I-beams: manual and automated. Traditional manual layup and forming methods are inefficient, have poor quality, and are technically limited, making them unsuitable for the manufacturing of large, thick, and primary load-bearing components. Automated manufacturing is gradually becoming the manufacturing technology for these large, thick, and primary load-bearing components. The automated manufacturing of composite beams primarily relies on the automated tape laying and hot diaphragm forming process.

[0004] The automatic tape laying-hot diaphragm automatic forming process method involves automatic laying and forming dies used for hot diaphragms. The commonly used tooling scheme at this stage is: automatic laying of prepreg blanks on automatic laying tooling (commonly used on nearly flat surfaces) to form automatic tape laying blanks, which are transferred to the hot diaphragm forming die to complete the hot diaphragm forming process to form a hot diaphragm preform. The hot diaphragm preform is transferred from the hot diaphragm forming die to the curing forming die, and the hot diaphragm preform is detached from the hot diaphragm forming die and transferred to the curing forming die. The hot diaphragm preform has transfer and positioning risks, and brings deformation problems to the hot diaphragm preform.

[0005] The automated forming process for composite I-beams involves the manufacturing, positioning, and assembly of "upper C" and "lower C" preforms to form the I-beam blank, as well as the curing, packaging, and curing of the I-beam blank. Composite I-beams utilize a technical solution in which a thermal diaphragm forming mold and a curing forming mold are integrated into the same tooling. Considering the positioning and assembly of the "upper C" and "lower C" preforms to form the I-beam blank, one end of the C-shaped preform forming mold serves as a locating bushing, while the other end of the C-shaped preform forming mold serves as a locating metal pin. The locating bushings and locating metal pins of the forming molds cooperate to position and assemble the C-shaped preform forming molds, thereby forming the I-beam blank. This forming process is feasible for non-thermal diaphragm forming processes, but presents significant challenges for thermal diaphragm forming processes. Locating bushings and locating pins are generally manufactured as extensions of the tooling's molding surfaces at both ends. The locating pins must be designed to a certain height to ensure positioning, and they must also possess a certain dimensional rigidity. The hot diaphragm forming process relies heavily on the diaphragm material of the hot diaphragm forming equipment. The stretching of the diaphragm material drives the interlayer slipping of the fiber layers in the blank heated to a certain temperature, and bends the flat sheet. In order to ensure the stretching effect of the diaphragm material, the hot diaphragm forming mold generally requires that the profile height shall not exceed certain critical values, the tooling profile shall have as smooth a transition as possible, the outside of the tooling frame shall be closed, and the tooling profile shall not have obvious protrusions or depressions to avoid puncturing the diaphragm or affecting the stretching of the diaphragm. The positioning bushings and positioning pins on the forming mold, as obvious protrusions or depressions, obviously can no longer meet the requirements of the hot diaphragm process. The forming mold that eliminates the positioning bushings and positioning pins meets the requirements of the hot diaphragm process, but ensuring the positioning and combination of the "upper C" and "lower C" preforms to form the I-beam blank has become a new technical problem.

[0006] In view of the above technical problems, a forming tool for composite I-beams and a forming process method based on the forming tool were invented. The problems of transferring the "upper C" and "lower C" automatic tape-laying blanks to the forming mold for positioning and completing the hot diaphragm forming process were solved, forming the "upper C" and "lower C" hot diaphragm preforms. The positioning and combination of the "upper C" and "lower C" hot diaphragm preforms formed the I-beam blanks. Summary of the Invention

[0007] The purpose of the present invention is to invent a forming tool for a composite I-beam and a forming process method created based on the forming tool, which is suitable for automatic tape laying and hot diaphragm forming processes, and solves the problems of blank transfer and positioning in automated manufacturing. At the same time, a forming tool and a corresponding forming process method of a tool combination of an integral composite mold and a metal forming mold are proposed, and the integrated demolding of the composite mold is smoothly realized.

[0008] The technical solutions of the present invention are as follows:

[0009] The automated manufacturing method of a composite I-beam comprises the following steps:

[0010] First step, preparation of the forming tool

[0011] The forming tool is mainly composed of a forming die, a hot diaphragm forming die, and a full-carbon fiber integral composite tool. The beam-shaped part of the work structure composite material can be decomposed into an "upper C" structure and a "lower C" structure, and is commonly seen on one side of the profile with a "closing" trend (the profile included angle < 90°), and the other side of the profile with an "opening" trend (the profile included angle > 90°). The present application defines the "lower C" structure profile of the beam-shaped part of the work structure composite material as an "opening" trend, and the "upper C" structure as a "closing" trend.

[0012] The forming die material is INVAR steel, which is used for forming the "lower C" structure of the beam-shaped part of the work structure composite material. Under the premise of meeting the tool strength and tool precision, the forming die structure design is simplified, such as reducing the height of the forming die, adopting an obtuse angle design for the non-tool surface of the forming die, and adopting a closed design for the outer periphery of the forming die tool forming surface support frame. A bushing hole is designed in the web surface of the forming die, and the bushing hole is designed with 3 places. A disc type positioner is inserted into the bushing hole, and a conical pin and a cylindrical pin are designed at the center positions of both sides of the disc 6. The same ring groove is designed on both sides of the disc 6 for filling solid silicone rubber, and the groove cross-sectional area is slightly larger than the cross-sectional area of the hollow silicone rubber of a certain diameter, so as to achieve the purpose of filling the groove with silicone rubber under a certain pressure. A threaded hole is designed on the conical pin, which is used in cooperation with the ejector. The diameters of the conical pin and the cylindrical pin are consistent, and the conical pin is connected with the disc positioning disc in the form of threaded connection, so that the conical pin can be removed during the hot diaphragm preforming and curing forming packaging process, so as to prevent the diaphragm and vacuum bag from being pierced. The forming die is used as a common tool for hot diaphragm preforming and curing forming of the beam-shaped part of the work structure composite material. A base block is designed on one side of the forming die, and the base block and the forming die can be fixed in the direction of the arrow in the figure, so as to provide the rear seat force when the jack works.

[0013] The material of the hot diaphragm forming die is INVAR steel, which is used for forming the "upper C" structure of the composite beam part with the shape of the workpiece. On the premise of meeting the strength and precision of the tooling, the structure design of the hot diaphragm forming die is simplified, such as reducing the height of the hot diaphragm forming die, using an obtuse angle design for the non-tooling surface of the hot diaphragm forming die, and using a closed design for the periphery of the support frame of the tooling forming surface of the hot diaphragm forming die. The bushing hole is designed in the web surface of the hot diaphragm forming die, and the bushing hole is designed in three places. The disc type positioner is also inserted into the bushing hole. The hot diaphragm forming die adopts a split combined design, that is, it is composed of a hot diaphragm forming die split part and a hot diaphragm forming die split part. The hot diaphragm forming die split part and the hot diaphragm forming die split part are turned over through a lifting ring, positioned through a positioning pin, and fully combined through a clamping device to ensure the precision of the combined forming surface. The position of the bushing hole of the hot diaphragm forming die is consistent with the position of the bushing hole of the forming die. When the forming die and the hot diaphragm forming die are combined, the forming die is located below and is fixed as the basic tooling holding position. The hot diaphragm forming die needs to be turned over by 180° with the forming surface downward under the action of the lifting ring. The combination of the forming die and the hot diaphragm forming die is completed through the cooperation of the conical pin of the disc positioner on the forming die and the bushing hole on the hot diaphragm forming die.

[0014] The combination form of the forming die and the hot diaphragm forming die is not conducive to the hot pressure tank curing forming of the part, the heating efficiency is relatively low, and the self weight of the combined tooling is increased. Therefore, in order to improve the heating efficiency of the hot pressure tank curing forming of the part and reduce the self weight of the combined tooling, the present application proposes and uses a full-carbon fiber integral composite tooling to replace the hot diaphragm forming die and participate in the combination and curing forming of the composite beam part with the shape of the workpiece. The full-carbon fiber integral composite tooling has three openings at the corresponding positions, and the positions of the openings are consistent with the positions of the bushing holes of the hot diaphragm forming die and the forming die. The opening area is tangent to the disc of the disc positioner. The full-carbon fiber integral composite tooling has a box-shaped structure to maintain its structural rigidity and ensure the precision of the forming surface. In addition, the side of the full-carbon fiber integral composite tooling on the other side is reinforced and can be subjected to the force applied by a jack.

[0015] Second step: automatic tape laying of the prepreg blank

[0016] A professional automatic tape laying trajectory planning and design software is used to divide the structure into four parts, such as the "upper C" structure, the "lower C" structure, the left edge strip and the right edge strip based on the numerical model of the beam structure with the shape of the workpiece. The four parts are expanded into flat blank numerical models for automatic tape laying by the software, and the running track of the automatic tape laying is planned to finally form a program code that can be recognized by the automatic tape laying equipment. At the same time, a special 0-degree fiber twisting extrusion equipment is used to preform the 0-degree fiber twist at the left and right edge strips.

[0017] The automatic tape laying equipment such as M-torres lays the four-part flat plate blank stack structure of the relevant "upper C" structure, "lower C" structure, left edge strip, right edge strip and the like on a dedicated automatic tape laying layup tool, and after the layup is completed, an ultrasonic cutting knife integrated with the automatic tape laying equipment is used to cut a rectangular opening area on the flat plate blank stack structure corresponding to the "upper C" structure and the "lower C" structure, the rectangular opening area corresponds to a disc positioner in a corresponding forming die and a heat-sealing membrane forming die, the rectangular opening area and the disc positioner are in tangential relationship, and considering the rectangular opening area error and the disc positioner manufacturing error, the tangential distance between the rectangular opening area position and the disc positioner edge is between 0-1mm.

[0018] Third step: heat-sealing membrane preforming of the blank

[0019] The flat plate blank stack structure of the "upper C" structure and the "lower C" structure is transferred to the corresponding forming die and the heat-sealing membrane forming die, three disc positioners are placed on the forming surface of the forming die and the heat-sealing membrane forming die, and the positioning mode is tangential positioning of the rectangular opening area and the disc positioner. The forming die and the heat-sealing membrane forming die are transferred to the forming platform of the heat-sealing membrane forming equipment, the lifting ring is removed, the protruding parts such as the conical pin of the disc positioner on the forming die and the heat-sealing membrane forming die are removed, and the silicone rubber membrane of the heat-sealing membrane forming equipment is prevented from being damaged. Finally, the flat plate blank stack structure of the "upper C" structure and the "lower C" structure on the corresponding forming die and the heat-sealing membrane forming die undergoes a certain time, temperature and vacuum coupling effect, and the "upper C" structure and the "lower C" structure blank is formed on the forming surface of the forming die and the heat-sealing membrane forming die.

[0020] Fourth step: combination of the blanks to form a profile structure blank

[0021] After the heat-sealing membrane preforming, the disc positioner on the heat-sealing membrane forming die is removed, only the positioning bushing hole is retained, the heat-sealing membrane forming die is rotated by 180° through the lifting ring, the "upper C" structure blank faces downward, the conical pin on the disc positioner of the forming die is reinstalled, and the positioning and combination of the heat-sealing membrane forming die and the forming die are completed through the cooperation of the conical pin and the positioning bushing hole on the heat-sealing membrane forming die. The combined blank is vacuum compacted in the form of an integral packaging vacuum bag. Then, the heat-sealing membrane forming die split body part, the positioning pin of the heat-sealing membrane forming die split body part and the clamp are all removed, and the heat-sealing membrane forming die split body part and the heat-sealing membrane forming die split body part are separated from the "upper C" structure blank one by one using the lifting ring, and finally the complete separation of the heat-sealing membrane forming die is completed.

[0022] Fifth step: packaging and curing of the part

[0023] Lift and place the whole carbon fiber integrated composite tooling on the "upper C" structure blank, the positioning method is to use the disc positioner to position the whole carbon fiber integrated composite tooling opening area tangentially, considering the composite material opening area error and the disc positioner manufacturing error, the distance between the composite material opening area position and the edge of the disc positioner is between 0-1mm. The form of whole encapsulation vacuum bag is used to vacuum compact the combined blank. Then place the 0 degree fiber twist, left and right side edge strip blanks in turn to form a complete tool structure. Finally, heat pressing tank curing encapsulation is carried out, and the heat pressing tank curing program is run, and the curing parameters are mainly: pressure 0.6-0.8Mpa, constant temperature 180±6℃, constant temperature time 120-180min, temperature rising and falling rate 0.5-3℃ / min, atmospheric pressure throughout the process, and finally the tool structure part is cured and formed.

[0024] Step 6: demolding of the part

[0025] After curing and forming, all auxiliary materials used for curing are disassembled, the internal thread of the conical pin on the disc positioner is acted on by the ejector, the disc positioner is separated from the forming mold. The base block and the jack are placed on the forming mold, the jack is tightly attached to the base block and continuously works to apply force to the side of the whole carbon fiber integrated composite tooling, so that the whole carbon fiber integrated composite tooling slips and is separated from the inner surface of the part, then the whole carbon fiber integrated composite tooling is separated from the "upper C" structure blank, and then the "lower C" structure size characteristics of the tool structure part are used to integrally demold the tool structure part from the forming mold.

[0026] The beneficial effects of the present application are:

[0027] (1) The disc positioner is creatively proposed, which has multiple functions, such as automatic laying of the blank on the corresponding heat insulation film forming mold, positioning of the heat insulation film forming mold and the forming mold, positioning of the composite tooling on the part blank, etc. In addition, the disc positioner has a detachable function, the conical pin on the protruding surface is detached from the disc positioner after completing the positioning function, so that the disc positioner does not have a protruding structure, thereby not affecting the heat insulation film preforming and curing forming, and reducing the forming difficulty of preforming and curing forming.

[0028] (2) The present application discards the common structure layout of designing bushing holes on both sides of a set of heat insulation film mold and designing positioning pins on both sides of another set of mold. Because of the protruding structure design of such bushing holes and positioning pins, the heat insulation film function will be seriously affected, and even the film will be easily damaged. The disc positioner of the present application greatly improves the structure form of the heat insulation film mold.

[0029] (3) The present invention uses a set of forming dies as both a preforming tool for the thermal diaphragm and a curing forming tool, which ensures that the reference of one side of the blank is always guaranteed by the forming die throughout the whole process, reduces the risk of transferring and positioning the thermal diaphragm preform, has certain cost advantages, and ensures the accuracy of parts manufacturing.

[0030] (4) Using a full carbon fiber integral composite tooling to replace the thermal diaphragm mold to participate in the assembly and curing of the structural parts, greatly reducing the combined weight of the structural parts forming tooling. The corresponding composite tooling can be assembled and positioned manually, improving the tooling assembly and positioning efficiency. At the same time, the use of the composite tooling also improves the thermal efficiency of curing. At the same time, the present invention proposes a jack that evenly applies force to the full carbon fiber integral composite tooling, so that the composite tooling can overcome the adhesion and adsorption forces generated by the curing of the parts, and then the composite tooling can be easily separated from the part surface.

[0031] (5) Based on the inventive molding tooling, a corresponding molding process method for composite I-beams was developed, which is particularly suitable for the automated manufacturing of large-scale, integrated I-beam structures, and ensures the transfer and assembly quality of the uncured prepreg blanks of the composite I-beams, the curing packaging quality and demolding quality of the composite I-beams, and ultimately ensures the molding quality of the composite I-beams. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a structural diagram of an I-shaped composite beam;

[0033] Figure 2 Schematic diagram of the forming die structure;

[0034] Figure 3 (a) is a perspective view of the disc-type positioner structure;

[0035] Figure 3(b) is a cross-sectional view of the disc positioner structure;

[0036] Figure 4 Schematic diagram of the structure of the thermal diaphragm forming die;

[0037] Figure 5 It is a schematic diagram of the internal structure of the thermal diaphragm forming die;

[0038] Figure 6 It is a schematic diagram of the combination of the forming die and the thermal diaphragm forming die;

[0039] Figure 7 Schematic diagram of the combination of all-carbon fiber integral composite material tooling and forming die;

[0040] Figure 8 This is a partial enlarged view of the combination of the all-carbon fiber integral composite material tooling and the forming die;

[0041] Figure 9 Figure 3 is a partial enlarged view of the combination of the full carbon fiber monolithic composite tooling and the forming die;

[0042] Figure 10(a) is an open area diagram of the flat blank stack structure of the "upper C" structure and "lower C" structure;

[0043] Figure 10(b) is a positioning relationship diagram of the flat blank stack structure of the "upper C" structure and "lower C" structure and the disc positioner;

[0044] Figure 11(a) is a schematic diagram of the bushing hole of the thermal diaphragm forming die;

[0045] Figure 11(b) is a schematic diagram of the disc positioner and the automatic tape laying blank open area.

[0046] In the figure: 1 forming die, 2 thermal diaphragm forming die, 3 full carbon fiber monolithic composite tooling, 4 jack, 5 disc positioner, 6 disc, 7 conical pin, 8 cylindrical pin, 9 annular groove, 10 thermal diaphragm forming die split part, 11 thermal diaphragm forming die split part, 12 positioning pin, 13 clamp, 14 lifting ring, 15 open area, 16 side of the full carbon fiber monolithic composite tooling, 17 base block, 18 rectangular open area, 19 bushing hole. DETAILED DESCRIPTION

[0047] The specific embodiments of the present application will be described in detail below in conjunction with the technical solutions.

[0048] 1) Preparation of the forming tooling

[0049] The forming tooling is mainly composed of a forming die 1, a thermal diaphragm forming die 2, and a full carbon fiber monolithic composite tooling 3.

[0050] The beam-shaped composite material part of the work structure can be decomposed into an "upper C" structure and a "lower C" structure, and is commonly characterized by one side profile being a "closing" trend (profile included angle < 90°) and the other side profile being an "opening" trend (profile included angle > 90°). The present application defines the "lower C" structure profile of the beam-shaped composite material part of the work structure as an "opening" trend, and the "upper C" structure as a "closing" trend.

[0051] The material of the forming die 1 is INVAR steel, which is used for forming the "lower C" structure of the beam-shaped composite material part with a box section. On the premise of meeting the strength and precision of the tooling, the structure design of the forming die 1 is simplified, such as reducing the height of the forming die 1, adopting an obtuse angle design (30-60°) for the non-tooling surface of the forming die 1, and adopting a closed design for the periphery of the support frame of the tooling forming surface of the forming die 1. A bushing hole is designed on the web surface of the forming die 1, and three bushing holes are designed. A disc-type positioner 5 is inserted into the bushing hole. A conical pin 7 and a cylindrical pin 8 are designed on the two sides of the center of a disc 6 of the disc-type positioner 5. An annular groove 9 is also designed on the two sides of the disc 6 for filling solid silicone rubber. The cross-sectional area of the groove is slightly larger than the cross-sectional area of the hollow silicone rubber of a certain diameter (generally 5%-10% of the cross-sectional area of the hollow silicone rubber is taken as the interference amount), so that the silicone rubber can be fully filled in the groove under the action of a certain pressure. A threaded hole (the size of the threaded hole is R2.5mm-R4mm) is designed on the conical pin 7, so as to be matched with a pin lifter. The diameter of the conical pin 7 and the cylindrical pin 8 is kept consistent. The conical pin 7 is connected with the disc in a threaded connection manner, so that the conical pin 7 can be removed in the process of heat-separation membrane pre-forming and curing forming packaging, so as to prevent the conical pin 7 from piercing the membrane and the vacuum bag. The forming die 1 is a common tooling for the heat-separation membrane pre-forming and curing forming of the beam-shaped composite material part with a box section. A base block 17 is designed on one side of the forming die 1. The base block 17 and the forming die 1 can be fixed in the direction of the arrow in the figure, so as to provide a rear seat force for the operation of a jack 4.

[0052] The material of the heat-separation membrane forming die 2 is INVAR steel, which is used for forming the "upper C" structure of the beam-shaped composite material part with a box section. On the premise of meeting the strength and precision of the tooling, the structure design of the heat-separation membrane forming die 2 is simplified, such as reducing the height of the heat-separation membrane forming die 2, adopting an obtuse angle design (30-60°) for the non-tooling surface of the heat-separation membrane forming die 2, and adopting a closed design for the periphery of the support frame of the tooling forming surface of the heat-separation membrane forming die 2. A bushing hole is designed on the web surface of the heat-separation membrane forming die 2, and three bushing holes are designed. A disc-type positioner 5 is also inserted into the bushing hole. The heat-separation membrane forming die 2 adopts a split combination design, that is, the heat-separation membrane forming die is composed of split parts 10 and 11. The split parts 10 and 11 are rotated through a lifting ring 14, positioned through a positioning pin 12, and fully combined through a clamp 13, so as to ensure the precision of the combined forming surface. The position of the bushing hole of the heat-separation membrane forming die 2 is consistent with the position of the bushing hole of the forming die 1. When the forming die 1 and the heat-separation membrane forming die 2 are combined, the forming die 1 is located below and is fixed as the basic tooling. The heat-separation membrane forming die 2 needs to be turned over by 180° to make the forming surface downward under the action of the lifting ring. The combination of the forming die 1 and the heat-separation membrane forming die 2 is completed through the cooperation of the conical pin 7 of the disc positioner on the forming die 1 and the bushing hole on the heat-separation membrane forming die 2.

[0053] The combination of the forming die 1 and the hot diaphragm forming die 2 is not conducive to the hot pressure tank curing forming of the part, the heating efficiency is relatively low, and the self weight of the combined tooling is increased, therefore, in order to improve the heating efficiency of the hot pressure tank curing forming of the part and reduce the self weight of the combined tooling, the full-carbon fiber integral composite tooling 3 is proposed and used to replace the hot diaphragm forming die 2 to participate in the combined and curing forming of the beam type part of the work type structure composite material. The full-carbon fiber integral composite tooling 3 is opened at the corresponding position opening 3, and is consistent with the position of the bushing hole of the hot diaphragm forming die 2 and the position of the bushing hole of the forming die 1, and the opening area 15 is tangent to the disc in the disc positioner. The full-carbon fiber integral composite tooling 3 is in a box-shaped structure to maintain its structural rigidity, thereby ensuring the accuracy of the forming surface, and the other side end 16 is reinforced and can be subjected to the force of the jack 4.

[0054] 2) Automatic tape laying of the prepreg blank

[0055] Professional automatic tape laying track planning and design software is used, based on the beam type numerical model of the work type structure, the structure is divided into four parts of the upper C structure, the lower C structure, the left edge strip and the right edge strip, and the four parts are expanded into the flat blank numerical model for automatic tape laying by the software, and the automatic tape laying running track is planned, and finally the program code that can be recognized by the automatic tape laying equipment is formed. At the same time, a special 0-degree fiber twisting extrusion equipment is used to preform the 0-degree fiber twist at the left and right edge strips.

[0056] The automatic tape laying equipment such as M-torres lays the flat blank laminated structure of the four parts of the related upper C structure, lower C structure, left edge strip and right edge strip on the special automatic tape laying tooling, and after the laying is completed, the ultrasonic cutting knife integrated with the automatic tape laying equipment is used to cut a rectangular opening 18 on the flat blank laminated structure of the corresponding upper C structure and lower C structure, the rectangular opening 18 corresponds to the disc positioner 5 in the corresponding forming die 1 and hot diaphragm forming die 2, and the rectangular opening 18 is tangent to the disc positioner 5, considering the blank opening 18 error and the manufacturing error of the disc positioner 5, the distance between the position of the blank opening 18 and the tangent edge of the disc positioner 5 is between 0-1mm.

[0057] 3) Hot diaphragm preforming of the blank

[0058] The "upper C" structure and the "lower C" structure are transferred to the corresponding forming die 1 and the heat diaphragm forming die 2, and three disc positioners 5 are placed on the forming surface of the forming die 1 and the heat diaphragm forming die 2, and the positioning mode is that the blank opening area 18 is tangent to the disc positioner 5. The forming die 1 and the heat diaphragm forming die 2 are transferred to the forming platform of the heat diaphragm forming equipment, the lifting ring is removed, the protruding parts such as the conical pin 7 of the disc positioner 5 on the forming die 1 and the heat diaphragm forming die 2 are removed, and the silica gel diaphragm of the heat diaphragm forming equipment is avoided from being damaged. Finally, the "upper C" structure and the "lower C" structure of the flat blank stack structure are formed on the corresponding forming die 1 and the heat diaphragm forming die 2 under the action of time, temperature and vacuum coupling, and the "upper C" structure and the "lower C" structure of the blank are completely attached to the forming surface of the forming die 1 and the heat diaphragm forming die 2.

[0059] 4) Blank combination to form a work structure blank

[0060] After the heat diaphragm preforming, the disc positioner 5 on the heat diaphragm forming die 2 is removed, only the positioning bushing hole 19 is reserved, the heat diaphragm forming die 2 is rotated by 180° through the lifting ring, the "upper C" structure blank faces downward, the conical pin 7 on the positioning disc 5 of the forming die is reinstalled, and the positioning and combination of the heat diaphragm forming die 2 and the forming die 1 are completed through the cooperation of the conical pin 7 and the positioning bushing hole 19 on the heat diaphragm forming die 2. The combined blank is vacuum compacted in the form of an integral packaging vacuum bag. Then, the positioning pins 12 and the clamps 13 of the split parts 10 and 11 of the heat diaphragm forming die 2 are all removed, and the split parts 10 and 11 are separated from the "upper C" structure blank one by one using the lifting ring 14, and finally the complete separation of the heat diaphragm forming die 2 is completed.

[0061] 5) Packaging and curing of parts

[0062] The all-carbon fiber integral composite tool 3 is lifted and placed on the "upper C" structure blank, and the positioning mode is that the disc positioner 5 is tangent to the all-carbon fiber integral composite tool opening area 15. Considering the opening 15 error of the composite tool and the manufacturing error of the disc positioner 5, the distance between the opening 15 position of the composite tool and the edge of the disc positioner 5 is between 0-1mm. The combined blank is vacuum compacted in the form of an integral packaging vacuum bag. Then, the 0 degree fiber twist, left and right side edge strip blanks are placed in sequence to form a complete work structure. Finally, the heat pressure tank curing packaging is carried out, and the heat pressure tank curing program is run, and the main curing parameters are: pressure 0.6-0.8Mpa, constant temperature 180±6℃, constant temperature time 120-180min, full process air, and finally the work structure part is cured and formed.

[0063] 6) Demolding of parts

[0064] After curing molding, all auxiliary materials used in curing are disassembled, a pin lifter is used to act on the internal thread of the conical pin 7 on the disc positioner 5, and the disc positioner 5 is separated from the molding mold. The jack base 17 and the jack 4 are placed on the molding mold 1, the jack 4 is tightly attached to the jack base 17 and continuously works to apply force to the whole carbon fiber integral composite material tool side surface 16, so that the whole carbon fiber integral composite material tool 3 slips and is separated from the inner type surface of the part, then the whole carbon fiber integral composite material tool 3 is integrally separated from the "upper C" structure blank, then the work structure part is integrally demolded from the molding mold 1 by using the size characteristics of the "lower C" structure of the work structure part.

Claims

1. An automated manufacturing method for composite I-beams, characterized in that: The following steps are involved: The first step is the preparation of molding tooling The molding tooling includes a molding die (1), a thermal diaphragm molding die (2), and a full carbon fiber integral composite material tooling (3); The molding die (1) tooling molding surface support frame periphery adopts closed design, the molding die (1) is designed with bushing holes on the web surface, the bushing holes are designed at 3 locations, the bushing holes are inserted into the bushing holes, the disc-type locator (5) is designed with tapered pins (7) and cylindrical pins (8) at the center position of the disc (6) on both sides of the disc (6), and annular grooves (9) are also designed on both sides of the disc (6) for filling solid silicone rubber, the cross-sectional area of ​​the groove is 5%-10% of the cross-sectional area of ​​the hollow silicone rubber, and a threaded hole is designed on the tapered pin (7); The diameters of the tapered pin (7) and the cylindrical pin (8) are kept consistent, and the tapered pin (7) is connected to the disc for positioning the disc in the form of a threaded connection; the forming die (1) is used as a common tool for the thermal diaphragm preforming and curing forming of the composite beam parts of the I-shaped structure; a base block (17) is designed at one end of the forming die (1), and the base block (17) is kept fixed to the forming die (1) so as to provide recoil force when the jack (4) is working; The periphery of the support frame of the tooling molding surface of the thermal diaphragm molding die (2) is designed to be closed; bushing holes are designed on the web surface of the thermal diaphragm molding die (2), and the bushing holes are designed at three locations, and a disc-type positioner (5) is also inserted into the bushing holes; the thermal diaphragm molding die (2) is composed of a thermal diaphragm molding die split part (10) and a thermal diaphragm molding die split part (11), and the turnover of the thermal diaphragm molding die split part (10) and the thermal diaphragm molding die split part (11) is achieved by a hanging ring (14), and the positioning is achieved by a positioning pin (12), and the thermal diaphragm molding die split part (10) and the thermal diaphragm molding die split part (11) are combined by a clamp (13), thereby ensuring the precision of the molding surface after matching; The position of the bushing hole of the thermal diaphragm forming die (2) is consistent with the position of the bushing hole of the forming die (1); when the forming die (1) and the thermal diaphragm forming die (2) are combined, the forming die (1) is located at the bottom and is fixed in the basic tooling holding position, and the thermal diaphragm forming die (2) needs to be turned 180 degrees under the action of the lifting ring to turn the forming surface downward, and the combination of the forming die (1) and the thermal diaphragm forming die (2) is completed by the cooperation of the tapered pin (7) of the disc positioner on the forming die (1) and the bushing hole on the thermal diaphragm forming die (2); Step 2: Automatic tape laying of prepreg blanks The automatic tape laying equipment lays the flat-plate blank stacking structure of the four parts of the "upper C" structure, the "lower C" structure, the left edge strip, and the right edge strip on a dedicated automatic tape laying and laying tool. After the laying is completed, the ultrasonic cutting knife integrated in the automatic tape laying equipment is used to cut a rectangular opening area (18) on the corresponding flat-plate blank stacking structure of the "upper C" structure and the "lower C" structure. The rectangular opening area (18) corresponds to the disc locator (5) in the corresponding forming mold (1) and the thermal diaphragm forming mold (2). The rectangular opening area (18) maintains a tangent relationship with the disc locator (5). The tangent distance between the position of the rectangular opening area (18) and the edge of the disc locator (5) is between 0 and 1 mm. Step 3: Hot diaphragm preforming of the blank The flat sheet blank stacking structure of the "upper C" structure and the "lower C" structure is transferred to the corresponding forming mold (1) and the thermal diaphragm forming mold (2), and three disc positioners (5) are placed on the forming surfaces of the forming mold (1) and the thermal diaphragm forming mold (2), and the positioning method is that the rectangular opening area (18) is tangentially positioned with the disc positioner (5); the forming mold (1) and the thermal diaphragm forming mold (2) are transferred to the forming platform of the thermal diaphragm forming equipment, the lifting ring (14) is removed, and the protruding part of the tapered pin (7) of the disc positioner (5) on the forming mold (1) and the thermal diaphragm forming mold (2) is removed to avoid damaging the silicone diaphragm of the thermal diaphragm forming equipment; finally, the flat sheet blank stacking structure of the "upper C" structure and the "lower C" structure is formed on the corresponding forming mold (1) and the thermal diaphragm forming mold (2) under a certain time, temperature and vacuum coupling, forming the "upper C" structure and the "lower C" structure blank that are completely attached to the forming surface of the forming mold (1) and the thermal diaphragm forming mold (2); Step 4: The blanks are combined to form the I-shaped structural blanks After the hot diaphragm is preformed, the disc positioner (5) on the hot diaphragm forming die (2) is removed, and only the positioning bushing hole (19) thereof is retained. The hot diaphragm forming die (2) is rotated 180 degrees by the lifting ring so that the "upper C" structure blank faces downward, and the tapered pin (7) on the disc positioner (5) of the forming die is reinstalled. The tapered pin (7) is matched with the positioning bushing hole (19) on the hot diaphragm forming die (2) to complete the positioning and combination of the hot diaphragm forming die (2) and the forming die (1); The assembled blank is vacuum compacted in the form of an overall packaging vacuum bag; then, the heat diaphragm forming mold split part (10) and the positioning pin (12) and the clamp (13) of the heat diaphragm forming mold split part (11) of the heat diaphragm forming mold (2) are completely disassembled, and the heat diaphragm forming mold split part (10) and the heat diaphragm forming mold split part (11) are separated from the "upper C" structure blank one by one using the lifting ring (14), and finally the heat diaphragm forming mold (2) is completely separated; Step 5: Packaging and curing of parts Lift and place the all-carbon fiber integral composite material tooling (3) on the "upper C" structural blank, and position it by using a disc positioner (5) to be tangentially positioned with the opening area (15) of the all-carbon fiber integral composite material tooling; vacuum compact the assembled blank in the form of an overall packaging vacuum bag; then place the 0-degree fiber twist and left and right side edge strip blanks in sequence to form a complete tooling structure; and finally perform autoclave curing and packaging; Step 6: Demolding of parts After the solidification molding, all auxiliary materials used for the solidification of the parts are removed, and a pin lifter is used to act on the internal thread of the tapered pin (7) on the disc locator (5) to separate the disc locator (5) from the molding die; a base block (17) and a jack (4) are placed on the molding die (1), and the jack (4) is pressed against the base block (17) and continuously works to apply force to the side of the all-carbon fiber integral composite material tooling, so that the all-carbon fiber integral composite material tooling (3) slides and separates from the inner surface of the part, and then the all-carbon fiber integral composite material tooling (3) is separated from the "upper C" structural blank as a whole, and then the "lower C" structural size feature of the work structure part is used to demould the work structure part as a whole from the molding die (1).

2. The automated manufacturing method for composite I-beams according to claim 1, wherein: In the first step, a full carbon fiber integral composite material tooling (3) is used to replace the thermal diaphragm forming mold (2). The full carbon fiber integral composite material tooling (3) has 3 openings at corresponding positions, and is consistent with the bushing hole position of the thermal diaphragm forming mold (2) and the bushing hole position of the forming mold (1). The opening area (15) maintains a tangent relationship with the disc in the disc positioner (5); the full carbon fiber integral composite material tooling (3) is a box-shaped structure to maintain its structural rigidity and thus ensure the accuracy of the forming surface. The side surface (16) of the full carbon fiber integral composite material tooling on the other side is reinforced and can be applied with force by the jack (4).

3. The automated manufacturing method for composite I-beams according to claim 1, wherein: In the first step, the forming die (1) and the heat diaphragm forming die (2) are made of INVAR steel, and the threaded hole size on the tapered pin (7) is R2.5mm-R4mm.

4. The automated manufacturing method for composite I-beams according to claim 1, wherein: In the fifth step, the tangent distance between the position of the composite material tool opening area (15) and the edge of the disc positioner (5) is between 0 and 1 mm.

5. The automated manufacturing method for composite I-beams according to claim 1, wherein: In the fifth step, the curing parameters are mainly as follows: pressure 0.6-0.8Mpa, constant temperature 180±6°C, constant temperature time 120-180min, heating and cooling rate 0.5-3°C / min, full exposure to the atmosphere, and finally curing to form the structural parts.

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