Large-size h-shaped composite beam thermal diaphragm forming tool and forming method

Abstract

The application discloses a large-size h-shaped composite beam hot diaphragm forming tool and forming method and belongs to the technical field of composite material design and manufacturing. The h-shaped composite beam forming is decomposed into one L-shaped preform, one C-shaped preform and one flat plate preform by adopting the hot diaphragm forming process. Firstly, according to the designed layer, the flat plate layer group is formed by tape laying or manual lay-up, and then the L-shaped preform, the C-shaped preform and the flat plate preform are formed by the hot diaphragm forming process. Finally, the three preforms and the "0 degree fiber filling" layer are combined together, and the h-shaped preform is obtained by the hot diaphragm forming process again. The application simplifies the lay-up operation, improves the production efficiency, avoids the R angle area lay-up bridging, and guarantees the h-shaped composite beam profile quality and layer position precision.

Description

Technical Field

[0001] This invention belongs to the field of composite material design and manufacturing technology, and relates to a heat insulation film forming tooling and forming process for a large-size H-shaped composite beam. A heat insulation film forming tooling for an H-shaped composite beam is specially designed to ensure the shape and forming quality of the parts. Background Technology

[0002] The integral molding technology for large-size composite material parts has become a key technology in the integrated design and manufacturing of composite materials. It can reduce the number of parts and fasteners, thereby reducing structural weight and lowering production costs. The material design and structural design of composite materials, as well as the material molding and component molding, are completed simultaneously and inseparable, fully demonstrating the integrated design and manufacturing characteristics of integrally molded composite material structures.

[0003] Large-size H-shaped composite beams are mainly used in large-size wing panels to improve the rigidity and strength of the wing panels and ensure the overall structural integrity of the aircraft. Therefore, higher requirements are placed on H-shaped composite beams. H-shaped composite beams have small cross-sectional dimensions, a large slenderness ratio, and high requirements for surface and dimensional accuracy. They are manufactured using manual lay-up / autoclave molding methods, typically employing a solid male mold in conjunction with a soft mold. For H-shaped composite beams with high surface and dimensional accuracy requirements, due to the small radius (R) of the beam, bridging is prone to occur during the lay-up process. This leads to significant problems with improper fit between the solid core mold and the soft mold, affecting not only the internal quality of the part but also causing thickness deviations. Therefore, the pre-forming quality of H-shaped composite beams has become a key factor affecting the overall molding quality of H-shaped composite beams. Summary of the Invention

[0004] The purpose of this invention is to provide a molding fixture and process for forming thermal insulation films on large-size H-shaped composite beams. This solution addresses the difficulties in forming H-shaped composite beams, the challenges in beam height control, radius defects, and overall shape quality. It improves the overall strength and stiffness of the H-shaped composite beams, fully demonstrating the advantages of composite materials, and also increases the production efficiency of parts manufacturing. This manufacturing method has been applied to a certain type of large composite component and has achieved excellent design and performance results.

[0005] The composite material h-shaped beam of the present invention is composed of “C” ply 1, “Z” ply 2, “flat” ply 3 and “0° fiber-filled” ply 4.

[0006] This invention is achieved through the following technical solution:

[0007] The H-type composite beam is manufactured using a thermal diaphragm molding process, which breaks down the process into three preforms: an L-shaped preform, a C-shaped preform, and a flat preform. First, according to the designed layup, flat layup assemblies are formed by tape laying or manual stacking. Then, the L-shaped, C-shaped, and flat preforms are formed using a thermal diaphragm molding process. Finally, the three preforms are combined with a "0° fiber-filled" layup, and a final thermal diaphragm molding process is performed to obtain the H-type preform. The H-type composite beam can be manufactured using an autoclave molding process.

[0008] A large-size h-shaped composite beam thermal insulation film forming tooling includes a layup mold 5, a positioning pin 6, a "flat" layup mold 7, a "0° fiber-filled" layup mold cover plate 8, a "0° fiber-filled" layup mold 9, a C-shaped thermal insulation film forming mold 10, an L-shaped thermal insulation film forming mold 11, an L-shaped cover plate 12, and an L-shaped cover plate forming mold 13.

[0009] The “C” ply 1 and “Z” ply 2 are unfolded based on the web surface and designed as a ply mold 5 with a flat structure. A 100mm allowance is left in both the length and width directions for encapsulation. A positioning pin 6 is designed outside the allowance in the length direction.

[0010] The "flat" layup die 7 is designed with the "flat" layup 3 as the mold surface.

[0011] The “0° fiber-filled” layup die cover plate 8 and the “0° fiber-filled” layup die 9 form a double-sided hard die structure to obtain the “0° fiber-filled” layup, which can effectively guarantee the surface dimensions.

[0012] The C-type heat insulation film forming mold 10 is designed according to the "C" layup 1 mold surface, and the length direction of the allowance is designed with positioning pins 6.

[0013] L-shaped heat insulation film forming mold 11 is designed according to the "Z" layup 2 molding surface. The length direction of the mold is designed with positioning pins 6 to unfold the molding surface of the "Z" layup 2 away from the "0° fiber filling" layup 4 into a plane, leaving a 20mm-30mm margin.

[0014] L-shaped cover plate forming mold 13 is designed with "Z" lay-up 2 for the mold surface and is used to manufacture L-shaped cover plate 12. The length margin is designed with positioning pins 6.

[0015] The positioning pins designed for the following molds are in the same position: 5. "Flat" layer layup mold 7. C-type heat insulation film forming mold 10. L-type heat insulation film forming mold 11. L-type cover plate 12. L-type cover plate forming mold 13.

[0016] A method for forming a heat-insulating membrane using the above-mentioned h-shaped composite beam includes the following steps:

[0017] 1) Unfold the “C” ply 1 and “Z” ply 2 of the h-type composite beam and make holes on the ply cut pieces that are the same size and position as the positioning pins 6; unfold the “flat” ply 3 and make its outline consistent with the “flat” ply stacking mold 7.

[0018] 2) After unfolding, the “C” ply 1 and “Z” ply 2 are laid onto the ply stacking mold 5, and the ply is positioned by the positioning pin 6. The “flat” ply 3 is laid onto the “flat” ply stacking mold 7 and then vacuum-compacted at room temperature.

[0019] 3) Lay the “0° fiber-filled” layer 4 onto the “0° fiber-filled” layer stacking mold 9, cover it with the “0° fiber-filled” layer stacking mold cover plate 8, and perform vacuum compaction at room temperature;

[0020] 4) Using the molding surface and positioning pin 6 as a reference, the compacted “C” layup 1 is positioned on the C-type heat insulation film forming mold 10, and the compacted “Z” layup 2 is positioned on the L-type heat insulation film forming mold 11. The preforms are then bent into the corresponding shapes through the heat insulation film forming process.

[0021] 5) Manufacture an L-shaped cover plate 12 of composite material on the L-shaped cover plate forming mold 13, and trim the web surface of the cured L-shaped cover plate 12 according to the "Z" layup 2, and bevel the edges.

[0022] 6) The preformed C-shaped “C” layup 1 preform, the L-shaped “Z” layup 2 preform, the “flat” layup 3 preform, and the “0° fiber-filled” layup 4 preform are assembled into one piece by positioning pins and fixed on the C-shaped heat insulation film forming mold 10. The “flat” layup stacking mold 7 is attached to the “flat” layup 3 preform, and the L-shaped cover plate 12 is attached to the L-shaped “Z” layup 2 preform.

[0023] 7) The h-shaped preform is obtained by heating and pressurizing on a thermal diaphragm device;

[0024] 8) After overall encapsulation, the prepreg is cured in an autoclave according to the curing parameters;

[0025] 9) Remove the product from the tank and trim its shape to produce an h-shaped composite beam.

[0026] The beneficial effects of this invention are as follows: This invention employs a thermal diaphragm molding process, decomposing the formation of an H-shaped composite beam into one L-shaped preform, one C-shaped preform, and one flat preform. First, according to the designed layup, flat layup assemblies are formed through tape laying or manual stacking. Then, the L-shaped, C-shaped, and flat preforms are formed using a thermal diaphragm molding process. Finally, the three preforms are combined with a "0° fiber-filled" layup, and a final thermal diaphragm molding process is performed to obtain the H-shaped preform. This invention simplifies the layup operation, improves production efficiency, avoids bridging in the R-corner area, and ensures the surface quality and layup position accuracy of the H-shaped composite beam. Attached Figure Description

[0027] Figure 1 This is a structural diagram of an h-type composite beam.

[0028] Figure 2 Schematic diagram of the "C" ply and "Z" ply stack.

[0029] Figure 3 A schematic diagram of a "flat" layer-by-layer layup mold.

[0030] Figure 4 A schematic diagram of a "0° fiber-filled" layup mold.

[0031] Figure 5 This is a schematic diagram of a C-type thermal insulation film forming mold.

[0032] Figure 6 This is a schematic diagram of an L-shaped thermal insulation film forming mold.

[0033] Figure 7 This is a schematic diagram of an L-shaped cover plate forming mold.

[0034] Figure 8 This is a schematic diagram of the thermal diaphragm molding process.

[0035] Figure 9 This is a schematic diagram of the prefabrication process for an H-shaped composite beam.

[0036] In the diagram: 1 "C" layup; 2 "Z" layup; 3 "flat" layup; 4 "0° fiber-filled" layup; 5 layup die; 6 locating pin; 7 "flat" layup die; 8 "0° fiber-filled" layup die cover plate; 9 "0° fiber-filled" layup die; 10 C-type heat insulation film forming die; 11 L-type heat insulation film forming die; 12 L-type cover plate; 13 L-type cover plate forming die. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this invention clearer, the specific embodiments of this invention will be described in detail below with reference to the accompanying drawings, taking the radial annular groove propellant column structure as an example.

[0038] A certain H-shaped composite beam has dimensions of 5200mm × 300mm × 6mm (maximum thickness) and is to be assembled with composite wall panels. High requirements are placed on the shape and thickness of the H-shaped composite beam. Therefore, this manufacturing solution was adopted.

[0039] The H-type composite beam is manufactured using a thermal diaphragm molding process, which breaks down the process into three preforms: an L-shaped preform, a C-shaped preform, and a flat preform. First, according to the designed layup, flat layup assemblies are formed by tape laying or manual stacking. Then, the L-shaped, C-shaped, and flat preforms are formed using a thermal diaphragm molding process. Finally, the three preforms are combined with a "0° fiber-filled" layup, and a final thermal diaphragm molding process is performed to obtain the H-type preform. The H-type composite beam can be manufactured using an autoclave molding process.

[0040] A large-size h-shaped composite beam thermal insulation film forming tooling includes a layup mold 5, a positioning pin 6, a "flat" layup mold 7, a "0° fiber-filled" layup mold cover plate 8, a "0° fiber-filled" layup mold 9, a C-shaped thermal insulation film forming mold 10, an L-shaped thermal insulation film forming mold 11, an L-shaped cover plate 12, and an L-shaped cover plate forming mold 13.

[0041] The “C” ply 1 and “Z” ply 2 are unfolded based on the web surface and designed as a ply mold 5 with a flat structure. A 100mm allowance is left in both the length and width directions for encapsulation. A positioning pin 6 is designed outside the allowance in the length direction.

[0042] The "flat" layup die 7 is designed with the "flat" layup 3 as the mold surface.

[0043] The “0° fiber-filled” layup die cover plate 8 and the “0° fiber-filled” layup die 9 form a double-sided hard die structure to obtain the “0° fiber-filled” layup, which can effectively guarantee the surface dimensions.

[0044] The C-type heat insulation film forming mold 10 is designed according to the "C" layup 1 mold surface, and the length direction of the allowance is designed with positioning pins 6.

[0045] L-shaped heat insulation film forming mold 11 is designed according to the "Z" layup 2 molding surface. The length direction of the mold is designed with positioning pins 6 to unfold the molding surface of the "Z" layup 2 away from the "0° fiber filling" layup 4 into a plane, leaving a 20mm-30mm margin.

[0046] L-shaped cover plate forming mold 13 is designed according to "Z" lay-up 2 mold surface and is used to manufacture L-shaped cover plate 12. The length direction of the excess is designed with positioning pin 6.

[0047] The positioning pins 6 designed for the following molds are in the same position: 5, 7, C-type heat insulation film forming mold, 10, L-type heat insulation film forming mold, 11, L-type cover plate, 12, and 13.

[0048] A method for forming a heat-insulating membrane using the above-mentioned h-shaped composite beam includes the following steps:

[0049] 1) Using the web surface as a reference, unfold “C” ply 1 and “Z” ply 2 into corresponding ply, add 30mm allowance around the ply, and make holes on the ply cutting piece that are the same size and position as the positioning pin 6. Unfold “flat” ply 3 and make its outline consistent with “flat” ply stacking mold 7.

[0050] 2) After unfolding, the “C” ply 1 and “Z” ply 2 are laid onto the ply stacking mold 5, and the ply is positioned by the positioning pin 6. The “flat” ply 3 is laid onto the “flat” ply stacking mold 7 and then vacuum-compacted at room temperature.

[0051] 3) Lay the “0° fiber-filled” layer 4 onto the “0° fiber-filled” layer stacking mold 9, cover it with the “0° fiber-filled” layer stacking mold cover plate 8, and perform vacuum compaction at room temperature;

[0052] 4) Using the molding surface and positioning pin 6 as a reference, the compacted “C” layup 1 is positioned on the C-type heat insulation film forming mold 10, and the compacted “Z” layup 2 is positioned on the L-type heat insulation film forming mold 11. The preforms are then bent into the corresponding shapes through the heat insulation film forming process.

[0053] 5) Manufacture an L-shaped cover plate 12 of composite material on the L-shaped cover plate forming mold 13, and trim the web surface of the cured L-shaped cover plate 12 according to the "Z" layup 2, and bevel the edges.

[0054] 6) The preformed C-shaped “C” layup 1 preform, the L-shaped “Z” layup 2 preform, the “flat” layup 3 preform, and the “0° fiber-filled” layup 4 preform are assembled into one piece by positioning pins 6 and fixed on the C-shaped heat insulation film forming mold 10. The “flat” layup stacking mold 7 is attached to the “flat” layup 3 preform, and the L-shaped cover plate 12 is attached to the L-shaped “Z” layup 2 preform.

[0055] 7) The h-shaped preform is obtained by heating and pressurizing on a thermal diaphragm device;

[0056] 8) After overall encapsulation, the prepreg is cured in an autoclave according to the curing parameters;

[0057] 9) After curing, the shape is trimmed to produce an h-shaped composite beam.

Claims

1. A method for forming an H-shaped composite beam thermal insulation film using a forming fixture, characterized in that, The tooling includes a layup die (5), a positioning pin (6), a "flat" layup die (7), a "0° fiber-filled" layup die cover plate (8), a "0° fiber-filled" layup die (9), a C-type heat insulation film forming die (10), an L-type heat insulation film forming die (11), an L-type cover plate (12), and an L-type cover plate forming die (13). The h-shaped composite beam is composed of "C" ply, "Z" ply, "flat" ply and "0° fiber-filled" ply; Among them, the "C" ply and the "Z" ply are unfolded based on the web surface and designed as a flat structure ply mold (5), with a 100mm margin in both length and width directions for encapsulation; The "flat" layup stacking mold (7) is designed with the "flat" layup as the mold surface; The "0° fiber-filled" layup die cover plate (8) and the "0° fiber-filled" layup die (9) form a double-sided hard die structure to obtain the "0° fiber-filled" layup and ensure the surface dimensions; The C-type heat insulation film forming mold (10) is designed according to the "C" layup molding surface; The L-shaped heat insulation film forming mold (11) is designed according to the "Z" layup molding surface. The side of the "Z" layup molding surface away from the "0° fiber filling" layup is unfolded into a plane, leaving a 20mm-30mm margin. The L-shaped cover plate forming mold (13) is designed according to the "Z" layering mold surface and is used to manufacture L-shaped cover plates (12). The layup die (5) has a length margin externally designed positioning pin (6); The C-type heat insulation film forming mold (10) has a locating pin (6) designed outside the length direction of the allowance. The L-shaped heat insulation film forming mold (11) has a locating pin (6) designed outside the length direction of the allowance; the L-shaped cover plate forming mold (13) has a locating pin (6) designed outside the length direction of the allowance. The method includes the following steps: 1) Unfold the "C" and "Z" plies of the h-type composite beam and make holes on the ply cut pieces that are the same size and position as the positioning pins (6); Unfold the "flat" ply and make its outline consistent with the "flat" ply stacking mold (7); 2) The unfolded "C" ply and "Z" ply are laid onto the ply stacking mold (5), and the ply are positioned by the positioning pin (6). The "flat" ply is laid onto the "flat" ply stacking mold (7), and vacuum compaction is performed at room temperature. 3) Lay the "0° fiber-filled" layer onto the "0° fiber-filled" layer stacking mold (9), cover it with the "0° fiber-filled" layer stacking mold cover plate (8), and perform vacuum compaction at room temperature; 4) Using the template surface and positioning pin (6) as a reference, the compacted "C" layup is positioned on the C-type heat insulation film forming mold (10), and the compacted "Z" layup is positioned on the L-type heat insulation film forming mold (11). The preforms are then bent into the corresponding shapes through the heat insulation film forming process. 5) Manufacture an L-shaped cover plate (12) of composite material on the L-shaped cover plate forming mold (13), trim the web surface of the cured L-shaped cover plate (12) according to "Z" ply, and bevel the edges; 6) The preform C type "C" layup preform, L type "Z" layup preform, "flat plate" layup preform, and "0° fiber filling" layup preform are combined by positioning pins into one body and fixed on the C type hot diaphragm forming mold (10). The "flat plate" layup layup mold (7) is attached to the "flat plate" layup preform, and the L type cover plate (12) is attached to the L type "Z" layup preform; 7) Heating and pressurizing on the hot diaphragm device to obtain an h type preform; 8) After overall packaging, curing is performed in a hot press tank according to the curing parameters of the prepreg; 9) Out of the tank and profile finishing to produce an h type composite beam.

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