A near net size composite structure carbon fiber piercing preform and its weaving method

Abstract

The application discloses a near-net-size composite structure carbon fiber puncture preform, which comprises an X-Y direction composite structure and a Z direction fiber vertically puncturing the X-Y direction composite structure; a horizontal section of the X-Y direction composite structure is a regular n-polygon with a center opening, n=4m, m=2, 3, 4...; and the Z direction fiber is arranged in the X-Y direction composite structure row by row. The application further discloses a near-net-size composite structure carbon fiber puncture preform and a weaving method thereof. The advantages are as follows: the carbon fiber puncture preform in the form of an octagonal prism (or a dodecahedral prism, a hexadecahedral prism, etc.), a hollow, a near-rotating body, and a near-net-size can be directly woven into a shape, secondary cutting is not needed, and raw materials can be saved; the use amount of the Z direction steel needle can be reduced, the puncture resistance is reduced, and the forming of a large-size puncture preform becomes possible; the use amount of the Z direction steel needle is greatly reduced, the steel needle replacement workload is reduced by comparison, the forming efficiency is improved, and the production cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of carbon fiber puncture preform and its weaving method, especially a kind of near net size composite structure carbon fiber puncture preform and its weaving method. BACKGROUND

[0002] Carbon fiber puncture preform is three-dimensional high strength, high isotropic degree, whole structure strength is good, and the weaving material of excellent mechanical properties, carbon / carbon composite material processed with it has excellent ablation resistance, temperature impact resistance, whole structure strength, three-dimensional mechanical properties etc., is widely used in high-end fields such as aviation, aerospace.

[0003] At present, the puncture preform weaving process commonly used in China is to use the steel needle matrix arranged in advance to carry out overall needling and compaction on carbon fiber weftless cloth, weftless cloth / tire, woven fabric and other sheet materials, and then manually complete the carbon fiber replacement Z direction steel needle operation to obtain the puncture preform.

[0004] Its problems are as follows:

[0005] 1. The forming mode and preform structure design method are single, and only the rectangular cuboid preform can be woven, for the case of using the preform to make hollow cylindrical structure, the near net size workpiece cannot be completed at one time, and the near net size puncture preform needs to be obtained after cutting; Therefore, a certain amount of preform needs to be cut off, resulting in large raw material loss in the production process;

[0006] 2. For the preparation of large size puncture preform, because the number of Z direction steel needle is extremely large, the operation resistance increases sharply, and the steel needle array control is difficult during the puncture process, so that the large size puncture preform cannot be prepared;

[0007] 3. Because the amount of Z direction steel needle is large, and the Z direction steel needle needs to be replaced manually, and the replacement operation of the Z direction steel needle corresponding to the cut preform part is equivalent to invalid work, resulting in low production efficiency and high production cost.

[0008] 4. Because there is no horizontal (X-Y) direction yarn laying, the control of the steel needle at the edge of the steel needle array is difficult during the Z direction steel needle replacement process. SUMMARY

[0009] In order to solve the above problems, the first purpose of the present application is to provide a near net size composite structure carbon fiber puncture preform, and the second purpose of the present application is to provide a near net size composite structure carbon fiber puncture preform and its weaving method.

[0010] The first purpose of the present application is implemented by the following technical scheme:

[0011] A near-net-size composite structure carbon fiber piercing preform, comprising an X-Y direction composite structure and a Z direction fiber vertically piercing the X-Y direction composite structure; the horizontal section of the X-Y direction composite structure is a central opening regular n-polygon (n=4m, m=2, 3, 4…); the Z direction fiber is arranged in the X-Y direction composite structure in a certain interval row by row.

[0012] Further, the X-Y direction composite structure comprises a plurality of layers of plane layer structures and a plurality of layers of yarn layer structures, and the plane layer structures and the yarn layer structures are alternately overlapped;

[0013] Each of the plane layer structures is composed of a plurality of layers of plane layers vertically overlapped, and the total thickness of each of the plane layer structures is 5-10 mm;

[0014] Each of the yarn layer structures is composed of one or more yarn layers vertically overlapped, and each of the yarn layers comprises four layers of yarns, wherein:

[0015] The first layer of yarns: the first yarn is arranged in the direction parallel to any side of the plane layer, passes through the gap between the first row of Z direction fibers and the second row of Z direction fibers close to the side, and is arranged in a zigzag manner back and forth until the laying path of the first yarn covers 1 / 2 of the area of the plane layer; the laying path of the second yarn is centrally symmetric to the laying path of the first yarn with the center of the plane layer as the center;

[0016] The second layer of yarns: the laying path of the first layer of yarns is rotated clockwise by 90° around the center of the plane layer, which is the laying path of the second layer of yarns;

[0017] The third layer of yarns: the laying path of the first layer of yarns is mirror-symmetric along the direction perpendicular to the yarn direction of the first yarn, which is the laying path of the third layer of yarns;

[0018] The fourth layer of yarns: the laying path of the second layer of yarns is mirror-symmetric along the direction parallel to the yarn direction of the first yarn, which is the laying path of the fourth layer of yarns.

[0019] Further, the plane layer is a composite layer obtained by overlapping a carbon fiber woven weftless cloth and a carbon fiber web.

[0020] Further, the Z direction fiber is a carbon fiber.

[0021] The second object of the application is implemented by the following technical scheme:

[0022] A weaving method of a near-net-size composite structure carbon fiber piercing preform, comprising the following steps:

[0023] S1, layer cutting: according to the X-Y direction size of the woven forming puncture preform, the raw material is cut into a central opening n-sided polygon (n=4m, m=2, 3, 4…) plane layer;

[0024] S2, needle selection and arrangement: according to the size and shape of the plane layer cut in S1, the thickness size and Z-direction fiber spacing parameters of the woven forming puncture preform, select the puncture steel needle with appropriate length, diameter and number; arrange the selected puncture steel needle on the steel needle array limiting device according to the shape of the plane layer;

[0025] S3, steel needle array retention: according to the Z-direction fiber spacing parameters of the woven forming puncture preform, add array retention devices with corresponding size in the steel needle array arranged in S2;

[0026] S4, needling and laying: select multiple layers of plane layers cut in S1 vertically overlapped and laid on the steel needle array obtained in S3, use a template to needle the multiple layers of plane layers into the steel needle array; then, use carbon fiber continuous filaments to perform one or more cycles of laying operation in the gap between the steel needles of the steel needle array above the plane layer according to the laying rule; repeat the needling and laying operation until the thickness size of the woven forming puncture preform is reached, and obtain a to-be-compacted composite structure;

[0027] S5, compaction: move the to-be-compacted composite structure obtained in S4 to a pressing device for compaction operation, and compact the X-Y direction plane layer to a designed density value to obtain an X-Y direction composite structure;

[0028] S6, carbon fiber replaces Z-direction steel needle: use a thickness retaining device to fix the X-Y direction composite structure obtained in S5, and move it to a steel needle replacement workbench, use carbon fiber to complete the steel needle replacement in sequence and horizontally reciprocating row by row until the used puncture steel needles are replaced, and obtain a puncture preform.

[0029] Further, the raw material in S1 is a composite layer obtained by overlapping carbon fiber woven weftless cloth and carbon fiber web.

[0030] Further, in S4, the total thickness of the plane layer for each needling is 5-10 mm.

[0031] Further, the laying rule in S4 is:

[0032] The first layer of laying yarn: the first yarn is laid in a serpentine manner through the gap between the first and second piercing needles close to the edge of the plane layer in a direction parallel to the edge, until the laying path of the first yarn covers 1 / 2 of the area of the plane layer; the laying path of the second yarn is centrally symmetric to the laying path of the first yarn with the center of the plane layer as the center;

[0033] The second layer of laying yarn: the laying path of the first layer of laying yarn is rotated 90° clockwise around the center of the plane layer, and the laying path of the second layer of laying yarn is obtained;

[0034] The third layer of laying yarn: the laying path of the first layer of laying yarn is mirror-symmetric in a direction perpendicular to the yarn direction of the first yarn, and the laying path of the third layer of laying yarn is obtained;

[0035] The fourth layer of laying yarn: the laying path of the second layer of laying yarn is mirror-symmetric in a direction parallel to the yarn direction of the first yarn, and the laying path of the fourth layer of laying yarn is obtained;

[0036] After the above four layers of laying yarn are completed, a cycle of laying yarn operation is completed.

[0037] Advantages of the present application:

[0038] 1. The eight-prism (or twelve-prism, sixteen-prism, etc.), hollow, nearly-rotary body-shaped, near-net-dimension carbon fiber piercing preform can be directly woven and formed, without the need for secondary cutting, which can save raw materials;

[0039] 2. The use amount of Z-direction steel needles can be reduced, the piercing resistance is reduced, and the formation of large-size piercing preforms becomes possible;

[0040] 3. The use amount of Z-direction steel needles is greatly reduced, the corresponding steel needle replacement workload is reduced by comparison, the forming efficiency is improved, and the production cost is reduced;

[0041] 4. Through the introduction of carbon fiber laying operation, the laid carbon fiber can limit and maintain the piercing steel needle, which reduces the difficulty of controlling the steel needle array in the piercing process, is also beneficial to the formation of large-size piercing preforms, and can also improve the hoop strength of the preform and the isotropy of the X-Y direction performance.

[0042] 5. By laying multiple cycles of yarn in a local part, the local continuous fiber content can be improved, and the mechanical properties and ablation resistance of the part can be improved. BRIEF DESCRIPTION OF DRAWINGS:

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art 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.

[0044] Figure 1 This is a schematic diagram of the planar ply structure in Example 1;

[0045] Figure 2 This is a schematic diagram of the overall puncture preform obtained by alternating overlapping of planar lay-up structure and yarn layer structure, that is, a schematic diagram of the overall puncture preform prepared by the method of Example 2.

[0046] Figure 3 A schematic diagram of the puncture preform obtained by using multiple yarn layer structures for local height and alternating overlapping planar lay-up structures and yarn layer structures for the remaining parts, which is also a schematic diagram of the puncture preform prepared by the method of Example 3.

[0047] Figure 4 This is a schematic diagram of the yarn layer structure in the puncture preform in Example 1;

[0048] Figure 5 This is a schematic diagram of the planar ply of the steel needle array in Examples 2 and 3;

[0049] Figure 6 This refers to the laying path of the first yarn during the first layer of yarn laying process in Examples 2 and 3;

[0050] Figure 7 These are schematic diagrams showing the completion of the first layer of yarn laying in Examples 2 and 3;

[0051] Figure 8 This is a schematic diagram showing the completion of one cycle of yarn laying operation in Examples 2 and 3.

[0052] In the diagram: 1. Puncture needle; 2. Planar layup; 3. Puncture preform; 4. Yarn layer structure; 5. Yarn; 6. Z-direction fiber. Detailed implementation method:

[0053] 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.

[0054] Embodiment 1

[0055] A near-net-size composite structure carbon fiber piercing preform, comprising an X-Y direction composite structure and a Z direction fiber 6 piercing the X-Y direction composite structure vertically; the horizontal section of the X-Y direction composite structure is a central-holed regular n-gon (n=4m, m=2, 3, 4…); the Z direction fiber 6 is arranged in the X-Y direction composite structure row by row.

[0056] The X-Y direction composite structure comprises a plurality of layers of planar layer structures and a plurality of layers of yarn layer structures 4, and the planar layer structures and the yarn layer structures 4 are alternately overlapped;

[0057] Each layer of planar layer structure 2 is composed of a plurality of layers of planar layer 2 overlapped vertically, and the total thickness of each layer of planar layer structure 2 is 5-10 mm;

[0058] Each layer of yarn layer structure 4 is composed of one or more yarn layers overlapped vertically, and each layer of yarn layer includes four layers of yarns, wherein:

[0059] The first layer of yarn: the first yarn 5 is inserted into the gap between the first row of Z direction fibers 6 and the second row of Z direction fibers 6 along the direction parallel to any one side of the planar layer 2, and is laid in a serpentine manner until the laying path of the first yarn 5 covers 1 / 2 of the total area of the planar layer 2; the laying path of the second yarn 5 is centrally symmetric to the laying path of the first yarn 5 with the center of the planar layer 2 as the center;

[0060] The second layer of yarn: the laying path of the first layer of yarn is rotated 90° clockwise around the center of the planar layer 2, which is the laying path of the second layer of yarn;

[0061] The third layer of yarn: the laying path of the first layer of yarn is mirror-symmetric along the direction perpendicular to the yarn 5 direction of the first yarn 5, which is the laying path of the third layer of yarn;

[0062] The fourth layer of yarn: the laying path of the second layer of yarn is mirror-symmetric along the direction parallel to the yarn 5 direction of the first yarn 5, which is the laying path of the fourth layer of yarn.

[0063] Further, the planar layer 2 is a composite layer obtained by overlapping a carbon fiber woven weftless cloth and a carbon fiber webbing; the yarn 5 is a carbon fiber filament, and the Z direction fiber 6 is a 1K, 3K or 6K carbon fiber.

[0064] Embodiment 2

[0065] A kind of weaving method of near net size composite structure carbon fiber puncture preform, according to once forming near net size composite structure carbon fiber puncture preform 3, effective outer diameter 500mm, effective inner diameter 200mm, height 300mm, volume density 0.75g / cm 3 , Z direction fiber 6 is double strand 6K carbon fiber, interval 2.4mm;Preform structure uses the structure that 5mm~10mm thickness plane layer 2 and one cycle 6K carbon fiber continuous fiber layer are alternately overlapped, as shown in Figure 2 Specifically includes the following steps:

[0066] S1, layer blanking: according to the X-Y dimension of the puncture preform 3 to be woven and formed, the raw material is cut into a central hole octagonal plane layer 2 by numerical control cutting bed, and a 5mm~10mm allowance should be left on the single side dimension of the plane layer 2 when blanking, the outer side length of the plane layer 2 is 207mm, and the inner side length is 83mm;The raw material is a composite layer obtained by overlapping carbon fiber woven weftless cloth and carbon fiber web.

[0067] S2, needle selection and arrangement: according to the size and shape of the plane layer 2 cut in S1, and the thickness dimension and Z direction fiber 6 interval parameters of the puncture preform 3 to be woven and formed, 340 puncture steel needles 1 of appropriate length and diameter are selected, and the straightness and length consistency of the puncture steel needles 1 are screened to ensure that the length deviation of the puncture steel needles 1 is ±0.5mm;The selected puncture steel needles 1 are arranged on the steel needle array limiting device according to the shape of the octagonal plane layer 2, and the number of steel needles in each column can be calculated in advance when arranging the needles;

[0068] S3, steel needle array retention: according to the Z direction fiber 6 interval parameters of the puncture preform 3 to be woven and formed, the corresponding size of array retention device is added in the steel needle array arranged in S2, the steel needle array is adjusted to 2.4mm steel needle interval, and the puncture steel needles 1 in the array are fully protected and position controlled, after the steel needle array is adjusted, the puncture steel needles 1 in the array are checked and replaced, and the steel needle array is operated;

[0069] S4, needling and layering: 10~20 layers of plane layer 2 cut in S1 are vertically overlapped and laid on the steel needle array obtained in S3, and the multilayer plane layer 2 is needled into the steel needle array by using a template, as shown in Figure 5As shown; then, using carbon fiber continuous filament to carry out one or more cycles of laying operation in the gap of the piercing needle 1 of the steel needle array above the planar laying layer 2 according to the laying rule, mainly controlling the tension of the yarn 5 during the laying process, ensuring that the laid yarn 5 has uniform binding force on the outermost piercing needle 1 of the steel needle array; repeat the operation of needling and laying until the thickness size of the piercing preform 3 to be woven is reached, and the composite structure to be compacted is obtained;

[0070] In S4, the total thickness of the planar laying layer 2 for each needling is 5-10 mm.

[0071] Further, the laying rule in S4 is:

[0072] First layer of laying: the first yarn 5 is inserted between the first row of piercing needles 1 and the second row of piercing needles 1 close to the edge of the planar laying layer 2 in a direction parallel to the edge, and is laid in a serpentine manner until the laying path of the first yarn 5 covers 1 / 2 of the total area of the planar laying layer 2, as shown. Figure 6 The laying path of the second yarn 5 is centered symmetric to the laying path of the first yarn 5 with the center of the planar laying layer 2, as shown. Figure 7

[0073] Second layer of laying: rotate the laying path of the first layer of laying by 90° clockwise around the center of the planar laying layer 2, and the laying path of the second layer of laying is obtained;

[0074] Third layer of laying: mirror the laying path of the first layer of laying along a direction perpendicular to the direction of the yarn 5 of the first yarn 5, and the laying path of the third layer of laying is obtained;

[0075] Fourth layer of laying: mirror the laying path of the second layer of laying along a direction parallel to the direction of the yarn 5 of the first yarn 5, and the laying path of the fourth layer of laying is obtained;

[0076] After the above four layers of laying are completed, one cycle of laying operation is completed, as shown. Figure 8

[0077] S5, compacting: move the composite structure to be compacted obtained in S4 to the pressing device for compacting operation, compact the planar laying layer 2 in X-Y direction to 300 mm thickness, and obtain the X-Y direction composite structure with volume density meeting the design requirements; for the needling and compacting operation of the near-net-size piercing preform 3 woven into a large size, a steel needle spacing maintaining device matched with the wall thickness of the preform and a pressing auxiliary device matched with the inner hole size of the piercing preform 3 are used for needling and compacting operation;

[0078] ​​S6, carbon fiber replaces Z-direction steel needle: use the thickness maintaining device to fix the X-Y direction composite structure obtained in S5, and move to the steel needle replacement workbench. According to the design requirements of the preform, use 1K, 3K or 6K carbon fiber, and complete the steel needle replacement in turn by horizontal reciprocating row by row until the used puncture steel needle 1 is replaced, so as to realize the chain type lock buckle weaving of the X-Y direction composite structure, and obtain the puncture preform 3.

[0079] Example 3:

[0080] A weaving method of a near net size composite structure carbon fiber puncture preform 3, according to a one-time forming near net size composite structure carbon fiber puncture preform 3, the effective outer diameter is 500mm, the effective inner diameter is 200mm, the preform volume density is divided into three sections: the surface to 100mm height range is 0.75g / cm 3 , the 100mm-200mm height range is 0.85g / cm 3 , and the 200mm-300mm range is 0.75g / cm 3 ; the Z-direction fiber 6 is double 6K carbon fiber with a spacing of 2.4mm; the preform structure: the 100mm-200mm height range adopts a plurality of cycles of 6K carbon fiber continuous filament paving structure; the rest adopts the structure of alternately overlapping the 5mm-10mm thick plane paving layer 2 and one cycle of 6K carbon fiber continuous fiber paving layer, as shown in Figure 3 . Specifically, the following steps are included:

[0081] S1, paving layer cutting: according to the X-Y direction size of the puncture preform 3 to be woven and formed, the raw material is cut into a central hole octagonal plane paving layer 2 by a numerical control cutting bed. When cutting, a 5mm-10mm allowance should be left for the single side size of the plane paving layer 2. The outer side length of the plane paving layer 2 is 207mm, and the inner side length is 83mm. The raw material is a composite paving layer obtained by overlapping carbon fiber woven weftless cloth and carbon fiber web.

[0082] S2, needle selection and arrangement: according to the size and shape of the plane paving layer 2 cut in S1, and the thickness size and Z-direction fiber 6 spacing parameters of the puncture preform 3 to be woven and formed, 340 puncture steel needles 1 with appropriate length and diameter are selected, and the straightness and length consistency of the puncture steel needles 1 are screened to ensure that the length deviation of the puncture steel needles 1 is ±0.5mm. The selected puncture steel needles 1 are arranged on the steel needle array limiting device according to the shape of the octagonal plane paving layer 2. The number of puncture steel needles 1 in each column can be calculated in advance when arranging the needles;

[0083] S3, steel needle array holding: according to the Z-direction fiber spacing parameters of the to-be-knitted forming puncture preform 3, array holding devices of corresponding sizes are added to the steel needle array arranged in S2, the steel needle array is adjusted to a 2.4 mm steel needle spacing, and the puncture steel needles 1 in the array are fully protected and positionally controlled. After the steel needle array is adjusted, the puncture steel needles 1 in the array that are in a poor state are checked and replaced, and the steel needle array needling operation is started;

[0084] S4, needling and laying: 10-20 layers of the planar lay 2 cut in S1 are vertically overlapped and laid on the steel needle array obtained in S3, and the multiple layers of planar lays 2 are needled into the steel needle array by using a template, as shown in FIG. 4; Figure 5 Then, one or more cycles of laying operations are performed in the gaps between the puncture steel needles 1 of the steel needle array above the planar lays 2 according to the laying rules, and the tension of the yarn 5 is mainly controlled in the laying process to ensure that the binding force of the laid yarn 5 on the outermost puncture steel needles 1 of the steel needle array is uniform. The needling and laying operations are repeated in this way until the thickness of the to-be-knitted forming puncture preform 3 is reached, and the to-be-compacted composite structure is obtained.

[0085] In S4, the total thickness of the planar lay 2 for each needling is 5-10 mm.

[0086] Further, the laying rules in S4 are as follows:

[0087] First layer of laying: the first yarn 5 is inserted between the first row of puncture steel needles 1 and the second row of puncture steel needles 1 close to the edge of the planar lay 2 in a direction parallel to the edge, and is laid in a snakelike manner until the laying path of the first yarn 5 covers 1 / 2 of the total area of the planar lay 2, as shown in FIG. 5; Figure 6 The laying path of the second yarn 5 is centrally symmetric to the laying path of the first yarn 5 with the center of the planar lay 2 as the center, as shown in FIG. 6; Figure 7

[0088] Second layer of laying: the laying paths of the first layer of laying are rotated clockwise by 90° around the center of the planar lay 2, and the laying paths of the second layer of laying are obtained;

[0089] Third layer of laying: the laying paths of the first layer of laying are mirror-symmetric along a direction perpendicular to the direction of the yarn 5 of the first yarn 5, and the laying paths of the third layer of laying are obtained;

[0090] Fourth layer of laying: the laying paths of the second layer of laying are mirror-symmetric along a direction parallel to the direction of the yarn 5 of the first yarn 5, and the laying paths of the fourth layer of laying are obtained;

[0091] After the above four layers of laying are completed, one cycle of laying operation is completed. As shown in FIG. 7, Figure 8 ​as shown.

[0092] S5, compaction: the to-be-compacted composite structure obtained in S4 is moved to a pressing device for compaction operation, the planar layer 2 in the X-Y direction is compacted to a thickness of 300 mm, and an X-Y direction composite structure with a volume density meeting the design requirement is obtained. For the moving and compaction operation of the near-net-size piercing preform 3 woven into a large-size shape, a steel needle spacing maintaining device matched with the wall thickness of the preform and a pressing auxiliary device matched with the inner hole size of the piercing preform 3 are used for the moving and compaction operation.

[0093] S6, carbon fiber replacing Z direction steel needle: the X-Y direction composite structure obtained in S5 is fixed by using a thickness maintaining device and is moved to a steel needle replacing workbench. According to the design requirement of the preform, 1K, 3K or 6K carbon fiber is used to complete the steel needle replacement in sequence and horizontally and reciprocally row by row until the used piercing steel needle 1 is completely replaced, and the chain type lock weaving of the X-Y direction composite structure is realized, and the piercing preform 3 is obtained.

[0094] Comparative Example 1:

[0095] A carbon fiber piercing preform 3 formed by a traditional method, with a volume density of 0.75 g / cm 3 , Z direction fibers are double 6K carbon fibers with a spacing of 2.4 mm; the X-Y direction is formed by laminating and compacting composite unit layers of 12K carbon fiber woven weftless cloth / carbon fiber net tire; after forming the piercing preform with an outer size of 500 mm x 500 mm x 300 mm, it is cut into a hollow octagonal prism piercing preform with an effective outer diameter of 500 mm, an effective inner diameter of 200 mm and a height of 300 mm. The corresponding piercing preform forming actual replacement steel needle is 43681, and the weight of the cut part of the preform is 16.6 Kg (becoming solid waste).

[0096] By comparing Example 1, Example 2 and Comparative Example 1, it can be concluded that:

[0097] In Example 1 and Example 2, the piercing preform 3 forming actual replacement steel needle is 30340, and the preform does not need to be cut after forming, and can directly realize the forming of the near-net-size piercing preform 3; because the steel needle used in the forming process is reduced by 30.6% compared with Comparative Example 1, the stitch resistance and compaction pressure value during forming are effectively reduced, and the steel needle replacement amount is also reduced, which is more suitable for the forming of large-size piercing preform 3 parts. By introducing the operation of laying yarn, the hoop strength is increased, the fiber content is improved, and the ablation performance is improved.

[0098] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A near-net-shape composite carbon fiber puncture preform, characterized in that, The component includes an XY-direction composite structure and a Z-direction fiber with a vertical puncture XY-direction composite structure; the horizontal cross-section of the XY-direction composite structure is a regular n-gon with a central opening, n=4m, m=2,3,4… …; the Z-direction fiber is inserted row by row into the XY-direction composite structure. The XY direction composite structure includes several planar ply structures and several yarn layer structures, and the planar ply structures and the yarn layer structures overlap alternately. Each of the planar ply structures is formed by vertically overlapping multiple planar ply structures, and the total thickness of each planar ply structure is 5 to 10 mm. Each yarn layer structure is formed by vertically overlapping one or more yarn layers, and each yarn layer includes four layers of yarn lay-up, wherein: First layer of yarn: The first yarn passes through the gap between the first row of Z-direction fibers and the second row of Z-direction fibers near any side of the planar layup, and is laid in a serpentine manner until the laying path of the first yarn covers 1 / 2 of the area of ​​the planar layup; the laying path of the second yarn is centrally symmetrical with respect to the laying path of the first yarn about the center of the planar layup. Second layer of yarn laying: Rotate the entire laying path of the first layer of yarn laying 90° clockwise around the center of the planar layer to obtain the laying path of the second layer of yarn laying; The third layer of yarn laying: The entire laying path of the first layer of yarn laying is mirrored symmetrically in a direction perpendicular to the yarn direction of the first yarn, which is the laying path of the third layer of yarn laying. Fourth layer of yarn laying: The entire laying path of the second layer of yarn is mirrored symmetrically in a direction parallel to the yarn direction of the first yarn, which is the laying path of the fourth layer of yarn. The Z-axis fiber is carbon fiber.

2. The near-net-shape composite carbon fiber puncture preform according to claim 1, characterized in that, The planar layup is a composite layup obtained by overlapping carbon fiber woven non-woven fabric and carbon fiber mesh.

3. A method for weaving a near-net-shape composite carbon fiber puncture preform according to any one of claims 1-2, characterized in that, Includes the following steps: S1. Layup material preparation: Based on the XY dimensions of the piercing preform to be woven, cut the raw material into planar layups of regular n-sided polygons with a central opening, n=4m, m=2,3,4… …; S2. Needle selection and arrangement: Based on the size and shape of the planar layup cut in S1, the thickness of the puncture preform to be woven, and the Z-axis fiber spacing parameters, select appropriate length, diameter, and number of puncture steel needles; arrange the selected puncture steel needles on the steel needle array limiting device according to the shape of the planar layup; S3, Steel needle array holding: Based on the Z-axis fiber spacing parameters of the piercing preform to be woven, an array holding device of corresponding size is added to the steel needle array arranged in S2. S4, Needling and Yarn Laying: Select multiple planar lay-ups obtained from S1, overlap them vertically, and lay them on top of the steel needle array obtained in S3. Use a template to insert the multiple planar lay-ups into the steel needle array. Then, using continuous carbon fiber filaments, one or more cycles of yarn laying operations are performed in the gaps between the piercing steel needles of the steel needle array above the planar layup, according to the yarn laying rules; the piercing and yarn laying operations are repeated until the thickness of the pierced preform to be woven is reached, and the composite structure to be compacted is obtained. S5. Compaction: The composite structure to be compacted obtained in S4 is moved to a pressurizing device for compaction operation. The planar layup in the XY direction is compacted to the design density value to obtain the composite structure in the XY direction. S6. Replacement of Z-direction steel needles with carbon fiber: The XY-direction composite structure obtained in S5 is fixed with a thickness holding device and moved to the steel needle replacement worktable. Using carbon fiber, the steel needles are replaced row by row in a horizontal reciprocating motion until the puncture steel needles are replaced, and a puncture preform is obtained.

4. The weaving method for a near-net-shape composite carbon fiber puncture preform according to claim 3, characterized in that, The raw material in S1 is a composite layup obtained by overlapping carbon fiber woven non-woven fabric and carbon fiber mesh.

5. The weaving method for a near-net-shape composite carbon fiber puncture preform according to claim 3, characterized in that, In S4, the total thickness of the planar layup of each puncture-resistant fabric is 5 to 10 mm.

6. The weaving method for a near-net-shape composite carbon fiber puncture preform according to claim 3, characterized in that, The yarn laying rule in S4 is as follows: First layer of yarn: The first yarn is inserted through the gap between the first row of piercing needles and the second row of piercing needles near any side of the planar layup, and is laid in a serpentine manner until the laying path of the first yarn covers 1 / 2 of the area of ​​the planar layup; the laying path of the second yarn is centrally symmetrical with respect to the laying path of the first yarn about the center of the planar layup; Second layer of yarn laying: Rotate the entire laying path of the first layer of yarn laying 90° clockwise around the center of the planar layer to obtain the laying path of the second layer of yarn laying; Third layer of yarn laying: The entire laying path of the first layer of yarn is mirrored symmetrically along the direction perpendicular to the yarn direction of the first yarn, thus obtaining the laying path of the third layer of yarn. Fourth layer of yarn laying: The entire laying path of the second layer of yarn is mirrored symmetrically in a direction parallel to the yarn direction of the first yarn, thus obtaining the laying path of the fourth layer of yarn. Once all four layers of yarn have been laid, one cycle of yarn laying operation is complete.

Images