A method for designing molding tooling for orthogonal mesh composite components with variable curvature and cross-section

Abstract

This invention discloses a molding tooling design method for orthogonal mesh composite components with variable curvature and cross-section, comprising the following steps: constructing a molding device for the inner surface of the non-through mesh of the composite component; constructing a pre-laying device for the non-through mesh sheet of the composite component; constructing a positioning device for the non-through mesh of the composite component; constructing a pre-compacting device for the through mesh sheet of the composite component; constructing a positioning device for the through mesh of the composite component; and assembling the molding device for the composite component. The design method of this invention uses different devices to mold the non-through mesh and through mesh on the orthogonal mesh composite component with variable curvature and cross-section, avoiding the problem of insufficient pressure transmission in the molding device after the large number of meshes on the orthogonal mesh composite component with variable curvature and cross-section, thus ensuring the molding quality of the orthogonal mesh composite component with variable curvature and cross-section.

Description

Technical Field

[0001] This invention belongs to the field of composite material component manufacturing technology, specifically relating to a molding tooling design method for orthogonal grid composite material components with variable curvature and variable cross-section. Background Technology

[0002] The thrust reverser in an aero-engine is a special mechanism. The variable curvature and variable cross-section orthogonal grid composite material component is an important part of it. The thrust reverser is a specially shaped device that guides the external airflow. It has the advantages of high thrust reverser efficiency, strong airflow control capability, and good reliability. In addition, its relatively independent reinforcing ribs can prevent further crack propagation when subjected to impact damage. It has been widely used in high bypass ratio turbofan engines.

[0003] Variable curvature and variable cross-section orthogonal mesh composite material components are composed of multiple through-grids and non-through-grids. The size of each grid cell varies, and the thickness of the ribs connecting the grids also varies. Therefore, the design of the molding device for variable curvature and variable cross-section orthogonal mesh composite material components becomes particularly critical and is also a key technology for molding this type of composite material structure.

[0004] Structural components made of metal materials are all machined as a whole using CNC machine tools, which can ensure the overall contour accuracy and the precision of each grid. However, the precision of structural components made of composite materials is ensured by the molding device and molding process. However, due to the attenuation characteristics of vacuum pressure transmission between metal molds, and the large number of grids in the variable curvature and variable cross-section orthogonal grid composite material components, the pressure transmission is not in place after encapsulation. Furthermore, the variable curvature and variable cross-section orthogonal grid composite material components contain both non-through and through grids, which cannot guarantee the molding quality of the orthogonal grid composite material components. Therefore, we propose a molding tooling design method for variable curvature and variable cross-section orthogonal grid composite material components. Summary of the Invention

[0005] The purpose of this invention is to provide a method for designing molding fixtures for orthogonal mesh composite components with variable curvature and variable cross-section, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for designing forming tooling for orthogonal mesh composite components with variable curvature and variable cross-section, comprising the following steps:

[0007] A. Construction of a non-through-mesh internal surface forming device for composite material components:

[0008] Establish a digital model of the non-penetrating mesh inner surface of the composite material component, obtain the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and construct a forming device for the non-penetrating mesh inner surface of the composite material component based on the obtained parameters of the digital model of the non-penetrating mesh inner surface of the composite material component.

[0009] B. Construction of a pre-laying device for non-through-mesh composite material components:

[0010] Obtain the process gap parameters between the non-through mesh sheet of the composite material component and the non-through mesh inner surface forming device of the composite material component; and construct the non-through mesh sheet pre-laying device of the composite material component based on the obtained process gap parameters.

[0011] C. Construction of a non-penetrating grid positioning device for composite material components:

[0012] Obtain the position parameters of the non-penetrating mesh of the composite component and the external surface parameters of the non-penetrating mesh pre-laying device for the composite component. Based on the obtained external surface parameters of the non-penetrating mesh pre-laying device for the composite component and the obtained position parameters of the non-penetrating mesh of the composite component, construct a non-penetrating mesh positioning device for the composite component.

[0013] D. Construction of a pre-compacting device for through-grid sheets in composite material components:

[0014] Obtain the parameters of the through-grid of the composite component, use airbags to lay composite material sheets at the through-grid of the composite component, and construct a pre-compaction device for the through-grid of the composite component based on the parameters of the composite material sheets laid at the through-grid of the composite component.

[0015] E. Construction of a through-grid positioning device for composite material components:

[0016] Obtain the position parameters of the through-grid of the composite material component, and construct a through-grid positioning device for the composite material component based on the obtained position parameters of the through-grid of the composite material component.

[0017] F. Assembly of composite material component molding device:

[0018] The composite material component non-through-mesh inner surface forming device, the composite material component non-through-mesh sheet pre-laying device, the composite material component non-through-mesh positioning device, the composite material component through-mesh sheet pre-compacting device, and the composite material component through-mesh positioning device are assembled to form an aircraft engine composite material component forming device.

[0019] Preferably, in step A, the construction of the non-penetrating mesh inner surface forming device for composite material components includes: establishing a digital model of the non-penetrating mesh inner surface of the composite material component, obtaining the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and constructing the non-penetrating mesh inner surface forming device for the composite material component based on the obtained parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, specifically including the following steps:

[0020] A1: Establish a digital model of the non-penetrating mesh inner surface of the composite material component, obtain the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and construct a metal male mold device for the non-penetrating mesh of the composite material component based on the obtained parameters of the digital model of the non-penetrating mesh inner surface of the composite material component.

[0021] A2: Based on the obtained numerical model parameters of the non-penetrating mesh inner surface of the composite material component, the non-penetrating mesh inner surface of the composite material component is offset inward to construct a non-penetrating mesh metal female mold device for the composite material component. The reserved gap formed between the combination of the non-penetrating mesh metal male mold device and the non-penetrating mesh metal female mold device for the composite material component is used to mold thermally expanded rubber.

[0022] A3: A rubber molding device for non-through-mesh metal male molds of composite components is constructed by thermal expansion rubber molding onto the non-through-mesh metal male mold device of composite components.

[0023] Preferably, in step A2, the distance by which the non-through mesh inner face of the composite material component is offset inward is determined based on the thickness of the molded thermally expanding rubber.

[0024] The thickness of the thermally expanded rubber is equal to the sum of the compression of the non-through-mesh sheet of the composite component and the reserved gap.

[0025] Preferably, in step B, the construction of the pre-laying device for non-through-mesh composite material components involves: obtaining the process gap parameters between the non-through-mesh composite material components and the non-through-mesh inner surface forming device; and constructing the pre-laying device for non-through-mesh composite material components based on the obtained process gap parameters. The specific steps are as follows:

[0026] The non-through mesh inner surface of the composite material component is offset inward, and the process gap parameters between the non-through mesh material sheet of the composite material component and the non-through mesh inner surface forming device of the composite material component are obtained. Based on the obtained process gap parameters, a pre-laying device for the non-through mesh material sheet of the composite material component is constructed.

[0027] The distance by which the inner face of the non-through mesh of the composite component is offset inward is the compression amount of the non-through mesh sheet of the composite component.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] The design method of this invention uses different devices to form non-through meshes and through meshes on orthogonal mesh composite material components with variable curvature and cross-section. This avoids the problem of insufficient pressure transmission within the forming device after the large number of meshes on the composite material component is packaged, thus ensuring the forming quality of the orthogonal mesh composite material component with variable curvature and cross-section. Furthermore, the forming tooling design method of the orthogonal mesh composite material component with variable curvature and cross-section of this invention has universality and provides a new approach for the design of components that require multiple combination devices for forming. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the orthogonal mesh composite material component with variable curvature and variable cross-section according to the present invention;

[0031] Figure 2 This is a schematic diagram of the non-through-mesh metal male mold device for composite material components according to the present invention;

[0032] Figure 3 This is a schematic diagram of the non-through-mesh metal male mold rubber molding device for composite material components according to the present invention;

[0033] Figure 4 This is a schematic diagram of the non-through-mesh metal mold device for composite material components according to the present invention;

[0034] Figure 5 This is a schematic diagram of the non-through-mesh sheet pre-laying device for composite material components according to the present invention;

[0035] Figure 6 This is a schematic diagram of the pre-compacting device for through-mesh composite material components according to the present invention;

[0036] Figure 7 This is a schematic diagram of the non-through-grid positioning device for composite material components of the present invention;

[0037] Figure 8 This is a schematic diagram of the structure of the composite material component through-grid positioning device of the present invention;

[0038] Figure 9 This is a schematic diagram of the airbag forming device of the present invention;

[0039] Figure 10 This is a schematic diagram of the composite material component molding device of the present invention.

[0040] In the figure: 1. Orthogonal mesh composite material component with variable curvature and cross-section; 2. Metal male mold device for non-through mesh composite material component; 3. Rubber molding device for metal male mold of non-through mesh composite material component; 301. Thermally expanded rubber; 4. Metal female mold device for non-through mesh composite material component; 5. Pre-laying device for non-through mesh composite material component; 6. Pre-compacting device for through mesh composite material component; 7. Positioning device for non-through mesh composite material component; 8. Positioning device for through mesh composite material component; 9. Airbag molding device; 901. Airbag; 10. Composite material component molding device. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Please see Figures 1-10 The method for designing forming fixtures for orthogonal mesh composite components with variable curvature and variable cross-section provided by the present invention includes the following steps:

[0043] A. Construction of a non-through-mesh internal surface forming device for composite material components:

[0044] Establish a digital model of the non-penetrating mesh inner surface of the composite material component, obtain the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and construct a forming device for the non-penetrating mesh inner surface of the composite material component based on the obtained parameters of the digital model of the non-penetrating mesh inner surface of the composite material component.

[0045] In step A, the construction of the non-penetrating mesh inner surface forming device for composite material components involves: establishing a digital model of the non-penetrating mesh inner surface of the composite material component, obtaining the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and constructing the non-penetrating mesh inner surface forming device for the composite material component based on the obtained digital model parameters. Specifically, this includes the following steps:

[0046] A1: Establish a digital model of the non-penetrating mesh inner surface of the composite material component, obtain the parameters of the digital model of the non-penetrating mesh inner surface of the composite material component, and construct a metal male mold device for the non-penetrating mesh of the composite material component based on the obtained parameters of the digital model of the non-penetrating mesh inner surface of the composite material component.

[0047] A2: Based on the obtained numerical model parameters of the non-penetrating mesh inner surface of the composite material component, the non-penetrating mesh inner surface of the composite material component is offset inward to construct a non-penetrating mesh metal female mold device for the composite material component. The reserved gap formed between the combination of the non-penetrating mesh metal male mold device and the non-penetrating mesh metal female mold device for the composite material component is used to mold thermally expanded rubber.

[0048] In step A2, the distance by which the non-through mesh inner face of the composite component is offset inward is determined based on the thickness of the molded thermally expanding rubber;

[0049] The thickness of the thermally expanded rubber is equal to the sum of the compression of the non-through-mesh sheet of the composite component and the reserved gap;

[0050] A3: A non-through-mesh metal male mold rubber molding device for composite material components is constructed by thermal expansion rubber molding onto the non-through-mesh metal male mold device for composite material components.

[0051] B. Construction of a pre-laying device for non-through-mesh composite material components:

[0052] Obtain the process gap parameters between the non-through mesh sheet of the composite material component and the non-through mesh inner surface forming device of the composite material component; and construct the non-through mesh sheet pre-laying device of the composite material component based on the obtained process gap parameters.

[0053] In step B, the construction of the pre-laying device for non-through-mesh composite material components involves: obtaining the process gap parameters between the non-through-mesh composite material components and the non-through-mesh inner surface forming device; and constructing the pre-laying device for non-through-mesh composite material components based on the obtained process gap parameters. The specific steps are as follows:

[0054] The non-through mesh inner surface of the composite material component is offset inward, and the process gap parameters between the non-through mesh material sheet of the composite material component and the non-through mesh inner surface forming device of the composite material component are obtained. Based on the obtained process gap parameters, a pre-laying device for the non-through mesh material sheet of the composite material component is constructed.

[0055] The distance by which the inner face of the non-through mesh of the composite component is offset inward is the compression amount of the non-through mesh sheet of the composite component.

[0056] C. Construction of a non-penetrating grid positioning device for composite material components:

[0057] Obtain the position parameters of the non-penetrating mesh of the composite component and the external surface parameters of the non-penetrating mesh pre-laying device for the composite component. Based on the obtained external surface parameters of the non-penetrating mesh pre-laying device for the composite component and the obtained position parameters of the non-penetrating mesh of the composite component, construct a non-penetrating mesh positioning device for the composite component.

[0058] D. Construction of a pre-compacting device for through-grid sheets in composite material components:

[0059] Obtain the parameters of the through-grid of the composite component, use an airbag forming device to lay composite material sheets at the through-grid of the composite component, and construct a pre-compacting device for the through-grid of the composite component based on the parameters of the composite material sheets laid at the through-grid of the composite component.

[0060] E. Construction of a through-grid positioning device for composite material components:

[0061] Obtain the position parameters of the through-grid of the composite material component, and construct a through-grid positioning device for the composite material component based on the obtained position parameters of the through-grid of the composite material component.

[0062] F. Assembly of composite material component molding device:

[0063] The composite material component non-through-mesh inner surface forming device, the composite material component non-through-mesh sheet pre-laying device, the composite material component non-through-mesh positioning device, the composite material component through-mesh sheet pre-compacting device, and the composite material component through-mesh positioning device are assembled to form an aircraft engine composite material component forming device.

[0064] In this embodiment, as Figure 1 The image shows a variable curvature and variable cross-section orthogonal mesh composite material component 1 formed by a molding device constructed using the design method of this invention. The variable curvature and variable cross-section orthogonal mesh composite material component includes two types of structures: non-through mesh and through mesh. According to... Figure 2 and Figure 4 The non-through-mesh metal male mold device 2 and the non-through-mesh metal female mold device 4 of the composite material component shown are combined to cure and mold the thermally expanded rubber 301 into a mold as shown. Figure 3 On the non-penetrating mesh metal male mold rubber molding device 3 shown, each non-penetrating mesh of the variable curvature and variable cross-section orthogonal mesh composite material component is formed... Figure 5 The prepreg is laid and pre-pressed on the non-through-mesh pre-laying device 5 for composite material components, as shown. Figure 7 The composite material component is positioned using the non-through grid positioning device 7, and each grid is positioned... Figure 5The composite component non-penetrating mesh sheet pre-laying device shown in Figure 5 transfers the composite component non-penetrating mesh sheet to... Figure 10 On the composite material component molding device 10 shown, the non-through-mesh sheet of the composite material component is removed, detached, and replaced. Figure 3 The non-through-mesh metal male mold rubber molding device 3 shown is used for the composite material component. Figure 9 The airbag forming device 9 shown forms an airbag 901, and after laying prepreg on the airbag 901, then... Figure 6 The pre-compaction device 6 for the through-grid sheet of the composite material component shown is installed and pre-compacted. Figure 8 The composite component through-grid positioning device 8, as shown, positions each through-grid piece of the composite component component, then lays the 0° direction reinforcing layer and transfers it to... Figure 10 On the composite material component molding device 10 shown, the components are assembled Figure 10 The composite material component molding device 10 shown is encapsulated and, after curing and demolding, forms a variable curvature and variable cross-section orthogonal mesh composite material component. It can use different devices to form non-through meshes and through meshes on the variable curvature and variable cross-section orthogonal mesh composite material component, avoiding the problem of insufficient pressure transmission in the molding device after the number of meshes on the variable curvature and variable cross-section orthogonal mesh composite material component is large. This ensures the molding quality of the variable curvature and variable cross-section orthogonal mesh composite material component. Moreover, the molding tooling design method of the variable curvature and variable cross-section orthogonal mesh composite material component of the present invention has universality and provides a new idea for the design method of forming components that require multiple combination devices.

[0065] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for designing a forming tool for a variable curvature and variable cross-section orthogrid composite member, characterized in that, The method comprises the following steps: A. Construction of the non-through grid inner surface forming device of the composite component: Establish a numerical model of the non-through grid inner surface of the composite component, obtain the parameters of the numerical model of the non-through grid inner surface of the composite component, and construct the non-through grid inner surface forming device of the composite component according to the obtained parameters of the numerical model of the non-through grid inner surface of the composite component; B. Construction of the non-through grid material sheet pre-laying device of the composite component: Obtain the process gap parameters between the non-through grid material sheet of the composite component and the non-through grid inner surface forming device of the composite component, and construct the non-through grid material sheet pre-laying device of the composite component according to the obtained process gap parameters; C. Construction of the non-through grid positioning device of the composite component: Obtain the position parameters of the non-through grid of the composite component and the outer surface parameters of the non-through grid material sheet pre-laying device of the composite component, and construct the non-through grid positioning device of the composite component according to the obtained outer surface parameters of the non-through grid material sheet pre-laying device of the composite component and the obtained position parameters of the non-through grid of the composite component; D. Construction of the through grid material sheet pre-compaction device of the composite component: Obtain the parameters of the through grid of the composite component, lay the composite material sheet at the through grid of the composite component using an air bag, and construct the through grid material sheet pre-compaction device of the composite component according to the parameters of the composite material sheet laid at the through grid of the composite component; E. Construction of the through grid positioning device of the composite component: Obtain the position parameters of the through grid of the composite component, and construct the through grid positioning device of the composite component according to the obtained position parameters of the through grid of the composite component; F. Assembly of the composite component forming device: Assemble the non-through grid inner surface forming device of the composite component, the non-through grid material sheet pre-laying device of the composite component, the non-through grid positioning device of the composite component, the through grid material sheet pre-compaction device of the composite component, and the through grid positioning device of the composite component to form the composite component forming device of the aircraft engine; In step A, the method specifically comprises the following steps: A1: Establish a numerical model of the non-through grid inner surface of the composite component, obtain the parameters of the numerical model of the non-through grid inner surface of the composite component, and construct the non-through grid metal male die device of the composite component according to the obtained parameters of the numerical model of the non-through grid inner surface of the composite component; A2: According to the obtained parameters of the numerical model of the non-through grid inner surface of the composite component, offset the non-through grid inner surface of the composite component to the inside, construct the non-through grid metal female die device of the composite component, and the reserved gap formed between the non-through grid metal male die device of the composite component and the non-through grid metal female die device of the composite component is used for forming the heat-expandable rubber; A3: Form the non-through grid metal male rubber forming device of the composite component by forming the heat-expandable rubber on the non-through grid metal male die device of the composite component.

2. The method of claim 1, wherein the method is characterized by: In step A2, the distance of offsetting the non-through grid inner surface of the composite component to the inside is determined according to the thickness of the formed heat-expandable rubber. The thickness of the thermal expansion rubber is equal to the sum of the compression amount of the non-through grid sheet of the composite material component and the reserved gap.

3. The method of claim 2, wherein the forming tooling design method of the variable-chirality variable-arcfion cross-section orthogrid composite member is characterized by: In step B, the construction of the non-through grid sheet pre-laying device of the composite material component: obtaining the process gap parameter between the non-through grid sheet of the composite material component and the non-through grid inner surface forming device of the composite material component, and constructing the non-through grid sheet pre-laying device of the composite material component according to the obtained process gap parameter, the specific steps are as follows: The non-through grid inner surface of the composite material component is biased inward, the process gap parameter between the non-through grid sheet of the composite material component and the non-through grid inner surface forming device of the composite material component is obtained, and the non-through grid sheet pre-laying device of the composite material component is constructed according to the obtained process gap parameter; The distance of the inward bias of the non-through grid inner surface of the composite material component is the compression amount of the non-through grid sheet of the composite material component.

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