A method for integrated forming and manufacturing of a high-gauge wall panel for a rocket

Abstract

The application discloses a forming manufacturing integrated method of a rocket high-finned wall plate and relates to the technical field of rocket high-finned wall plate manufacturing.The forming manufacturing integrated method comprises the following steps: step one, a winding stage: carbon fiber prepreg is wound on a core mold to form a fin; a grating is laid on the outside of the fin, and the two ends of the grating are respectively pre-fixed with the fin; step two, a curing stage: the core mold with the fin is placed in a skin, the fin is attached to the inner wall of the skin by providing an acting force by the core mold, the grating is located between the fin and the skin, the core mold maintains a certain pressure, the grating, the skin and the fin are heated, and the combination of the grating, the fin and the skin is realized; and step three, after the curing is completed, the core mold is withdrawn from the skin.The forming manufacturing integrated method of the rocket high-finned wall plate adopts carbon fiber to form the fin, realizes weight reduction and improvement of structural performance, information transmitted by the grating can detect real-time pressure and temperature at the interface, and the performance at the interface is convenient to observe.

Description

Technical Field

[0001] This invention relates to the field of rocket high-ribbed wall panel manufacturing technology, and in particular to an integrated method for forming and manufacturing rocket high-ribbed wall panels. Background Technology

[0002] In traditional technology, rocket panels, in order to achieve lightweighting, mostly employ high-ribbed panels. The processing method for high-ribbed panels is machining, specifically milling the ribs slowly into a single aluminum alloy raw material. With the increasing demand for rockets, existing technology has the following drawbacks: 1. Traditional machining requires milling the entire area outside the ribs, resulting in long manufacturing times; 2. Most of the raw aluminum alloy is milled out as scrap, leading to high costs; 3. It disrupts the internal flow lines of the metal, reducing the overall performance of the panel to some extent; 4. Aluminum alloy has a high density, resulting in insufficient lightweighting. In high-ribbed panels, the weight of the ribs is a significant contributor to the overall weight of the panel, so lightweighting the ribs is a highly effective means to improve the lightweighting of rocket high-ribbed panels. To address these issues, using composite materials instead of metal materials can significantly improve the lightweighting effect. However, the connection between composite materials and metal is complex, and traditional technology cannot guarantee that the interface performance between the two can be maintained while improving the lightweighting effect. Therefore, it is necessary to propose an integrated forming and manufacturing method for rocket high-ribbed panels. Summary of the Invention

[0003] The purpose of this invention is to provide an integrated method for forming and manufacturing rocket high-ribbed wall panels, which uses carbon fiber to form ribs, thereby achieving weight reduction and improved structural performance.

[0004] To achieve the above objectives, the present invention provides the following solution:

[0005] This invention provides an integrated method for forming and manufacturing a rocket high-ribbed wall panel, comprising the following steps:

[0006] Step 1, Winding Stage: The carbon fiber prepreg is wound around the mandrel to form ribs;

[0007] Step 2, Curing stage: Place the core mold with ribs into the skin, and use the core mold to apply force to make the ribs adhere to the inner wall of the skin. The core mold maintains a certain pressure and heats the skin and ribs to achieve the bonding of the ribs and skin.

[0008] Step 3: After curing, the core mold is removed from the skin.

[0009] Preferably, the core mold includes a soft mold and several hard molds, the hard molds are disposed on the outside of the soft mold, and there are gaps between adjacent hard molds. The gaps are used to wind carbon fiber prepreg. The cavity in the soft mold is used to fill liquid. The deformation of the soft mold is achieved by controlling the pressure of the liquid in the soft mold.

[0010] Preferably, the pressure inside the soft mold during the winding stage in step one is less than the pressure inside the soft mold during the curing stage in step two; and in step three, the pressure inside the soft mold when the core mold exits the skin is less than the pressure inside the soft mold during the winding stage in step one.

[0011] Preferably, the pressure inside the soft mold is P, and the relationship is as follows:

[0012]

[0013] Where σ is the yield strength of the skin material, t is the wall thickness of the skin, and r is the inner diameter of the skin;

[0014] The pressure inside the soft mold during the winding stage in step one is 0.1P-0.2P, and the pressure inside the soft mold during the curing stage in step two is 0.6P-0.8P.

[0015] Preferably, in the winding stage of step one, after the carbon fiber prepreg is wound onto the mandrel to form ribs, the mandrel and ribs are heated and kept warm for a period of time.

[0016] In the curing stage of step two, after the ribs are attached to the inner wall of the skin, the skin and ribs are heated to a temperature higher than that in step one, and kept at that temperature for a period of time before being cooled down.

[0017] Preferably, in the winding stage of step one, the overall fiber volume fraction of the carbon fiber prepreg remains unchanged during the weaving process, and the weaving angle is ±10 degrees.

[0018] In the curing stage of step two, the skin and ribs are cured with ultrasonic assistance at a frequency of 15-20 kHz and an amplitude of 21.4 to 23.6 μm.

[0019] Preferably, in the winding stage of step one, the cross-sectional area S of each layer of woven carbon fiber prepreg is... i for:

[0020]

[0021] Where d is the diameter of the carbon fiber prepreg, N ji N represents the amount of carbon fiber prepreg in each layer along the axial direction of the mandrel. wiC represents the amount of carbon fiber prepreg along the circumference of the mandrel in each layer, and C is the shrinkage rate.

[0022] Preferably, in the winding stage of step one, the amount of carbon fiber prepreg with the largest cross-section L max for:

[0023]

[0024] The minimum cross-section carbon fiber prepreg quantity L min for:

[0025]

[0026] Where m is the number of carbon fiber prepreg carriers along the axial direction of the mandrel, and n is the number of carbon fiber prepreg carriers along the circumferential direction of the mandrel. Moving radially inwards from the mandrel, the first layer has a cross-sectional area of ​​S1, the second layer has a cross-sectional area of ​​S2, and so on, with the innermost layer having a cross-sectional area of ​​S... a .

[0027] Preferably, in the winding stage of step one, the overall volume V of the carbon fiber prepreg is:

[0028]

[0029] Where, ρ m ρ is the density of the warp yarns. n denoted as the density of the weft yarn, and 'a' as the number of weaving layers.

[0030] Preferably, after step one and before step two, the grating is laid on the outside of the rib, and the two ends of the grating are pre-fixed to the rib respectively; in the curing stage of step two, when the core mold attaches the rib to the inner wall of the skin and the skin and the rib are heated, the resin overflowing from the carbon fiber prepreg wraps the grating between the rib and the skin.

[0031] The present invention achieves the following technical effects compared to the prior art:

[0032] In this invention, the pressure within the soft mold is adjusted during the winding stage to provide support. After the carbon fiber is wound to form ribs, the pressure within the soft mold increases, and heating is applied simultaneously to bond the carbon fiber ribs to the skin, forming a rocket high-ribbed wall panel. Compared with existing technologies, this invention, by using carbon fiber to form the ribs, has the following advantages: 1. The integrated forming process significantly improves the forming efficiency of the rocket high-ribbed wall panel, effectively reducing forming steps and shortening the work cycle; 2. It effectively reduces raw material loss, improves material utilization, and is conducive to improving economic efficiency; 3. It combines the advantages of both carbon fiber and metal materials, using heating and pressurization to solidify and connect the carbon fiber and metal materials, improving the connection strength between different material interfaces and enhancing product stability; 4. Carbon fiber has a low density, and using carbon fiber ribs can significantly reduce the weight of the wall panel while ensuring performance, improving the lightweight nature of the wall panel; 5. The information transmitted by the grating can detect the real-time pressure and temperature at the interface, facilitating the observation of interface performance and aiding in the management and monitoring of the overall forming process. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a schematic diagram of temperature and pressure curves for the integrated forming and manufacturing method of the rocket high-rib wall panel of the present invention.

[0035] Figure 2 This is a schematic diagram of the mandrel with carbon fiber prepreg wound according to the present invention.

[0036] Figure 3 This is a schematic diagram of the connection between the core mold and the skin of the present invention;

[0037] Figure 4 This is a schematic diagram showing the position of the grating of the present invention on the skin;

[0038] Wherein: 1-soft mold, 2-hard mold, 3-rib, 4-skin, 5-grating, 6-pre-tightening point. Detailed Implementation

[0039] 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.

[0040] The purpose of this invention is to provide an integrated method for forming and manufacturing rocket high-ribbed wall panels, which uses carbon fiber to form ribs, thereby achieving weight reduction and improved structural performance.

[0041] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0042] like Figures 1 to 4 As shown: This embodiment provides an integrated method for forming and manufacturing a rocket high-ribbed wall panel. The method employs a mandrel, which includes a soft mold 1 and several hard molds 2. The soft mold 1 is made of polyurethane, and the hard molds 2 are made of steel. Several rings of hard mold structures are arranged along the axial direction of the soft mold 1 on its outer side. Each ring of hard mold structures includes several hard molds 2 arranged circumferentially around the soft mold 1. Gaps exist between adjacent hard molds 2 for winding carbon fiber prepreg. The cavity inside the soft mold 1 is filled with liquid. Deformation of the soft mold 1 is achieved by controlling the pressure of the liquid inside the soft mold 1. The pressure inside the soft mold 1 is P, and its relationship with the skin 4 is as follows:

[0043]

[0044] Where σ is the yield strength of the skin material, t is the wall thickness of the skin, and r is the inner diameter of the skin;

[0045] The pressure inside the soft mold during the winding stage in step one is 0.1P-0.2P, and the pressure inside the soft mold during the curing stage in step two is 0.6P-0.8P.

[0046] The integrated forming and manufacturing method of a rocket high-ribbed wall panel according to this embodiment includes the following steps:

[0047] Step 1, winding stage: The pressure inside the soft mold 1 is maintained at 0.1P-0.2P, preferably 0.1MPa. The carbon fiber prepreg is wound around the gap of the core mold to form ribs 3. The core mold and ribs 3 are heated to 60°C and kept at that temperature for about 20 minutes.

[0048] During the winding stage, a four-step weaving method is used: First, prepare a suitable grade of carbon fiber prepreg (T300, T700, or T800 are optional). The carbon fiber prepreg is yarn pre-coated with resin to increase its adhesion and strength. Adjust the weaving machine to appropriate parameters so that it can accurately weave the carbon fiber prepreg into the gaps between the hard molds 2. The yarn carrier carries the carbon fiber prepreg and interweaves them according to a predetermined pattern and structure. During the weaving process, the yarn carrier needs to move along three directions: X, Y, and Z. The X direction refers to the circumference of the soft mold 1, the Y direction refers to the axial direction of the soft mold 1, and the Z direction refers to the radial direction of the soft mold 1. The movement of the yarn carrier in the X and Y directions interweaves the carbon fiber prepreg together to form a mesh structure that wraps around the sidewalls of the soft mold 1. The movement of the yarn carrier in the Z direction is the weaving along the radial direction of the soft mold 1. That is, the yarn carrier needs to move in the Z direction to interweave the carbon fiber prepreg onto the already woven mesh structure, thereby forming a three-dimensional structure.

[0049] In the gaps between the rigid molds 2, variable cross-section weaving is required. During the four-step weaving process, the initial cross-section must first be selected. Based on the dimensions of the initial cross-section, the quantity and arrangement of the carbon fiber prepreg are determined (preferably 1000 carbon fiber prepregs, 35 rows (parallel to the X direction), 35 columns (parallel to the Y direction), with the largest cross-section consisting of 6 main carbon fiber prepregs, followed by 62 carbon fiber prepregs surrounding the sidewalls of the rigid mold 2, and the remaining spaces filled with carbon fiber prepregs). At the enlarged cross-section, a yarn feeder is needed in each column of the arrangement to add yarn (i.e., add carbon fiber prepregs) to prevent disruption of the four-step weaving pattern.

[0050] This embodiment employs a method of adding yarn in rows during the enlarged cross-section weaving process. As the weaving cross-section expands, the yarn feeder adds yarn in rows along the inner side of the cross-section. During this process, the outermost yarn carrier moves outward to fill a gap, adding yarn row by row or column by column until the target cross-sectional area is reached. This process is repeated until the carbon fiber prepreg is tightly woven into the gaps between the rigid molds 2. Throughout the weaving process, the position and tension of each carbon fiber prepreg must be precisely controlled to ensure that the final composite material has a uniform structure and high strength.

[0051] In the winding stage of step one, the overall fiber volume fraction of the carbon fiber prepreg remains unchanged during the weaving process, and the weaving angle is ±10 degrees.

[0052] In this embodiment, during the winding stage of step one, the cross-sectional area S of each layer of woven carbon fiber prepreg is... i for:

[0053]

[0054] Where d is the diameter of the carbon fiber prepreg, N ji N represents the amount of carbon fiber prepreg in each layer along the axial direction of the soft mold 1. wi C represents the amount of carbon fiber prepreg along the circumferential direction of the soft mold 1 in each layer, and C represents the shrinkage rate.

[0055] In this embodiment, during the winding stage of step one, the quantity L of the carbon fiber prepreg with the largest cross-section... max for:

[0056]

[0057] The minimum cross-section of carbon fiber prepreg quantity L min for:

[0058]

[0059] Where m is the number of carbon fiber prepreg carriers along the axial direction of the soft mold 1, and n is the number of carbon fiber prepreg carriers along the circumferential direction of the soft mold 1. Moving inwards along the radial direction of the core mold, the first layer has a cross-sectional area of ​​S1, the second layer has a cross-sectional area of ​​S2, and so on, with the innermost layer having a cross-sectional area of ​​S... a .

[0060] In this embodiment, during the winding stage of step one, the overall volume V of the carbon fiber prepreg is:

[0061]

[0062] Where, ρ m ρ is the density of the warp yarns. n denoted as the density of the weft yarn, and 'a' as the number of weaving layers;

[0063] After step one and before step two, the grating 5 is laid on the outside of the rib 3. Resin is applied to both ends of the grating 5 and cured quickly to form pre-tightening points 6, which are pre-fixed to the rib 3 to ensure that the position of the grating 5 will not shift. The optical fiber at one end of the grating 5 extends to the outside of the rocket's high-rib wall panel and is connected to the demodulator to facilitate the observation of the interface performance.

[0064] Step 2, Curing Stage: The core mold with ribs 3 is placed into the skin 4. The pressure inside the soft mold 1 is 0.6P-0.8P, preferably 0.6MPa, to provide force for the core mold to adhere the ribs 3 to the inner wall of the skin 4. The core mold maintains a pressure of 0.6MPa. The skin 4 and ribs 3 are heated to 150℃ and held for about 255 minutes. As the temperature and pressure increase, the resin overflowing from the carbon fiber prepreg wraps the grating 5 between the ribs 3 and the skin 4, achieving the combination of ribs 3, grating 5 and skin 4. Then, the temperature is lowered.

[0065] Step 3: After curing, reduce the pressure inside the soft mold 1 to allow the core mold to exit the skin 4.

[0066] Specifically, in this embodiment, during the curing stage of step two, ultrasonic-assisted curing is used on the skin 4 and the ribs 3. The ultrasonic frequency is 15-20kHz, and the ultrasonic amplitude is 21.4 to 23.6μm, preferably 23.6μm at 15kHz or 21.4μm at 20kHz.

[0067] In this embodiment, during the winding stage, the pressure within the soft mold 1 is adjusted to provide support. After the carbon fiber is wound to form the ribs 3, the pressure within the soft mold 1 increases, and heating is applied simultaneously to bond the carbon fiber ribs 3 to the aluminum alloy skin 4, forming a rocket high-ribbed wall panel. This embodiment, by using carbon fiber to form the ribs 3, achieves structural weight reduction compared to existing technologies, and the use of carbon fiber also improves structural performance.

[0068] This specification uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An integrated method for forming and manufacturing a rocket high-ribbed wall panel, characterized in that: Includes the following steps: Step 1, Winding Stage: The carbon fiber prepreg is wound around the mandrel to form ribs; Step 2, Curing stage: Place the core mold with ribs into the skin, and use the core mold to apply force to make the ribs adhere to the inner wall of the skin. The core mold maintains a certain pressure and heats the skin and ribs to achieve the bonding of the ribs and skin. Step 3: After curing, the core mold is removed from the skin; The core mold includes a soft mold and several hard molds. The hard molds are disposed on the outside of the soft mold, and there are gaps between adjacent hard molds. The gaps are used to wind carbon fiber prepreg. The cavity inside the soft mold is used to fill liquid. The deformation of the soft mold is achieved by controlling the pressure of the liquid inside the soft mold. The pressure inside the soft mold during the winding stage in step one is less than the pressure inside the soft mold during the curing stage in step two; in step three, the pressure inside the soft mold when the core mold exits the skin is less than the pressure inside the soft mold during the winding stage in step one. In the winding stage of step one, after the carbon fiber prepreg is wound around the mandrel to form ribs, the mandrel and ribs are heated and kept warm for a period of time. In the curing stage of step two, after the ribs are attached to the inner wall of the skin, the skin and ribs are heated to a temperature higher than that in step one, and kept at that temperature for a period of time before being cooled down. During the winding stage, the pressure inside the soft mold remains constant; during the curing stage, the pressure inside the soft mold increases and then remains constant until the curing stage ends. During the curing stage, the pressure inside the soft mold remains constant as it cools down.

2. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 1, characterized in that: The pressure inside the soft mold is P The relationship is as follows: in, The yield strength of the skin material. t For the wall thickness of the skin, r The inner diameter of the skin; The pressure inside the soft mold during the winding stage in step one is 0.1P-0.2P, and the pressure inside the soft mold during the curing stage in step two is 0.6P-0.8P.

3. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 1, characterized in that: In the winding stage of step one, the overall fiber volume fraction of the carbon fiber prepreg remains unchanged during the weaving process, and the weaving angle is ±10 degrees. In the curing stage of step two, the skin and ribs are cured with ultrasonic assistance at a frequency of 15-20 kHz and an amplitude of 21.4 to 23.6 μm.

4. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 1, characterized in that: In the winding stage of step one, the cross-sectional area of ​​each layer of woven carbon fiber prepreg is... for: in, d The diameter of the carbon fiber prepreg is [missing information]. This refers to the amount of carbon fiber prepreg in each layer along the axial direction of the mandrel. This refers to the amount of carbon fiber prepreg in each layer along the circumferential direction of the mandrel. C This refers to the shrinkage rate.

5. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 1, characterized in that: In the winding stage of step one, the amount of carbon fiber prepreg with the largest cross-section for: Minimum cross-section carbon fiber prepreg quantity for: in, m The number of yarn carriers for the carbon fiber prepreg along the axial direction of the mandrel. n The number of yarn carriers for the carbon fiber prepreg along the circumference of the mandrel, extending radially inwards from the mandrel, is the cross-sectional area of ​​the first layer. S 1 The cross-sectional area of ​​the second layer is S2, and so on, with the cross-sectional area of ​​the innermost layer being... S a .

6. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 4, characterized in that: In the winding stage of step one, the overall volume of the carbon fiber prepreg... V for: in, The density of the warp yarns, The density of the weft yarn, a This refers to the number of weaving layers.

7. The integrated forming and manufacturing method for rocket high-ribbed wall panels according to claim 1, characterized in that: After step one and before step two, the grating is laid on the outside of the rib, and the two ends of the grating are pre-fixed to the rib respectively; in the curing stage of step two, when the core mold attaches the rib to the inner wall of the skin and the skin and rib are heated, the resin overflowing from the carbon fiber prepreg wraps the grating between the rib and the skin.

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