Low-stress bonding method for lightweight solid buoyancy material component
By adopting low-stress bonding methods in lightweight solid buoyant material components, changing the bonding method and reducing the bonding area, the problem of easy cracking of components under high water pressure is solved, and higher structural stress resistance and product qualification are achieved Rate.
Patent Information
- Application Number
- CN202411132915.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-19
- Publication Date
- 2024-12-17
AI Technical Summary
Existing lightweight solid buoyant material components are prone to cracking under high water pressure testing environments, resulting in poor structural mechanical properties and affecting the safety and economic losses of underwater equipment.
The low-stress bonding method is adopted, by changing the bonding method and reducing the bonding area, using block materials of the same height to splice along straight lines and planes, setting up bonding tapes and leaving gaps, and designing a water-permeable structure to reduce structural stress.
It effectively reduces the adhesive stress and structural stress between buoyant blocks, improves the structural stress resistance of the components, significantly improves the product's pass rate, and avoids cracking under high water pressure.
Smart Images
Figure CN119141892A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of buoyancy material manufacturing, and in particular relates to a low-stress bonding method for lightweight solid buoyancy material components. Background Art
[0002] Solid buoyancy material components are important components of various underwater equipment such as submersibles and underwater robots, providing the necessary positive buoyancy for various submersibles, underwater robots and other equipment; solid buoyancy material components play an important role in reducing the external dimensions of underwater equipment, increasing the equipment's payload, and improving the stability of the equipment's structure.
[0003] Due to the large volume of lightweight solid buoyancy material components, it is difficult to realize them by integral casting or other integral forming methods. The forming process route of lightweight solid buoyancy material components in the prior art is specifically as follows:
[0004] (1) Component splicing scheme design, that is, when processing components, the splicing scheme design of solid buoyancy material components is first carried out;
[0005] (2) Processing the bonding surface of the standard block or blank, that is, processing the bonding surface of a single solid buoyancy material standard block or blank, cleaning the surface after processing, and bonding it into a strip block with an adhesive; then processing the bonding surface of the strip block, cleaning the surface after processing, and bonding it into a layered block with an adhesive; then processing the bonding surface of the layered block, cleaning the surface after processing, and bonding it into a lightweight component blank with an adhesive; the component blank is finally machined to form the desired component shape.
[0006] Components formed by this method have different abilities to resist structural stress when combined together due to the differences in the individual mechanical properties of the standard blocks or blank materials used. In the subsequent water absorption test, weak points are formed at the standard blocks with poor mechanical properties, where cracks are prone to occur, which can cause the entire component to be scrapped. If cracks occur in the components during deep-sea operations, it will directly affect the safety of the underwater equipment and cause huge economic losses. Summary of the invention
[0007] In view of the shortcomings of the prior art, the present invention provides a low-stress bonding method for lightweight solid buoyancy material components. The method improves the process by changing the bonding method, reducing the bonding area, etc., and effectively solves the problem of cracking of lightweight solid buoyancy material components under high water pressure testing environment.
[0008] In order to achieve the purpose of the present invention, the following technical solutions are specifically adopted:
[0009] A low-stress bonding method for lightweight solid buoyancy material components comprises the following steps:
[0010] 1) Prepare block-shaped solid buoyancy materials of the same height;
[0011] 2) Taking block-shaped solid buoyancy materials as basic units, splicing and bonding them along a straight line to prepare strip-shaped solid buoyancy materials;
[0012] 3) Using strip-shaped solid buoyancy materials as basic units, splicing and bonding them along a plane to prepare a layered solid buoyancy material;
[0013] 4) Taking the layered solid buoyancy material as the basic unit, adhesive tapes are respectively arranged at both ends of the length direction or the width direction, and the upper and lower parts are spliced and bonded to prepare a lightweight solid buoyancy material component blank; the bonding length of the adhesive tape is the length or width of the layered solid buoyancy material, and the bonding width is the height of the block solid buoyancy material.
[0014] In step 4) of the present invention, if adhesive tapes are provided at both ends of the layered solid buoyancy material in the length direction, the bonding length of the adhesive tapes is the length of the layered solid buoyancy material; if adhesive tapes are provided at both ends of the layered solid buoyancy material in the width direction, the bonding length of the adhesive tapes is the width of the layered solid buoyancy material.
[0015] During the entire component bonding process, the bonding area between the layered solid buoyancy materials is the largest, and the generated bonding stress is also the largest. The present invention designs the bonding area between the layered solid buoyancy materials according to the thickness of the standard block multiplied by the length or width of the component, and verifies the bonding strength of the installation point or the lifting point bearing capacity according to 5 to 10 times the dead weight of the component; the remaining parts are not bonded or a gap of 0.5 to 1 mm is left. By reducing the bonding area between layers, gaps are formed between layers, forming a water-permeable structure, and the forces between layers are offset under the action of high water pressure. This structural design reduces the bonding stress between the buoyancy blocks and the structural stress generated in a high water pressure environment.
[0016] Preferably, there is a joint gap of 0.5 to 1 mm between upper and lower adjacent layered solid buoyancy materials.
[0017] Preferably, the bonding parts between the upper and lower adjacent layered solid buoyancy materials are arranged near the installation point or the lifting point of the lightweight solid buoyancy material component, so as to further ensure sufficient installation or lifting strength margin. The installation point refers to the structural feature designed in the drawings for fixing, fastening components or installing instruments and equipment; the lifting point refers to the thread or other form of structural feature designed in the drawings for lifting when installing components.
[0018] Preferably, the layered solid buoyancy material is perpendicular to an installation direction or a hoisting direction of the solid buoyancy material component.
[0019] Preferably, the density difference between the block solid buoyancy materials contained in each layered solid buoyancy material is within 0.01 g / cm 3 the following.
[0020] Further preferably, in the lightweight solid buoyancy material component, the density difference between the block solid buoyancy materials contained is within 0.01 g / cm 3 the following.
[0021] Material density is closely related to mechanical properties. Due to the different batches of solid buoyancy material standard blocks, the density of the standard blocks will be slightly different. The difference in density will lead to differences in mechanical properties. Standard blocks of different densities are bonded together, and the structural stress generated during use will also be different. The present invention ensures that the density of the block solid buoyancy material selected in the same layered solid buoyancy material, and even all the block materials selected for the entire lightweight solid buoyancy material component, is basically consistent through screening, so as to achieve basically consistent ability to resist structural stress and reduce the risk of cracking.
[0022] Preferably, adjacent strips of solid buoyancy materials are connected with staggered seams, and the distance between the staggered seams is not less than 50 mm;
[0023] Adjacent layered solid buoyancy materials are staggered, and the staggered distance is not less than 50 mm. In the splicing process of the buoyancy material component of the present invention, adjacent strip materials and adjacent layer materials are prevented from having through seams, thereby further reducing the bonding stress between block materials, strip materials and layer materials.
[0024] As a preference, the method further comprises the following steps:
[0025] 5) External shaping is performed on the lightweight solid buoyancy material component blank to obtain the lightweight solid buoyancy material component. The external shaping refers to achieving the shape and size required by the lightweight solid buoyancy material component.
[0026] Compared with the prior art, the present invention has the following advantages and effects:
[0027] (1) The low-stress bonding method of lightweight solid buoyancy material components provided by the present invention, compared with the existing technology, the improved process method makes the splicing structure more reasonable and reduces the structural stress caused by bonding and curing between standard blocks, strip blocks and layer blocks;
[0028] (2) The low-stress bonding method for lightweight solid buoyancy material components provided by the present invention achieves consistent mechanical properties of the block material by selecting block solid buoyancy materials with substantially uniform density as raw materials, and enhances the ability to resist structural stress during use;
[0029] (3) The low-stress bonding method for lightweight solid buoyancy material components provided by the present invention reduces the bonding area of the layered solid buoyancy material, forms gaps between layers, forms a water-permeable structure, and makes the water pressure between layers offset each other under the action of water pressure, thereby reducing the structural stress between the buoyancy blocks;
[0030] (4) The low-stress bonding method for lightweight solid buoyancy material components provided by the present invention has a small positive buoyancy loss of the components. The component hoisting part is subjected to a 4-fold deadweight load-bearing test, and the hoisting is performed three times. After five minutes each time, the lifting lugs are checked for cracks and the bonding parts are checked for cracks. The components are tested for water absorption under high water pressure, and no unqualified phenomena such as cracking are found. The product qualification rate is significantly improved to 100%. The problem of lightweight solid buoyancy material components being prone to cracking under high water pressure is solved. BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Figure 1 Schematic diagram of the process of the low-stress bonding method of the lightweight solid buoyancy material component in the embodiment.
[0032] Figure 2 Schematic diagram of a lightweight solid buoyancy material component in an embodiment (the upper left is a main view, the upper right is a left view, and the lower left is a top view).
[0033] Figure 3 Schematic diagram of the splicing scheme of the lightweight solid buoyancy material components in the embodiment (the top is the main view, the bottom is the top view, and point A is the enlarged view).
[0034] Figure 4 for Figure 3 Schematic diagram of the structure of the middle layer block 1 (the top is the main view, the bottom is the top view, the left side is the layer bonding blank view, and the right side is the layer processing view after bonding).
[0035] Figure 5 for Figure 3 Schematic diagram of the structure of the middle layer block 2 (the top is the main view, the bottom is the top view, the left is the layer bonding blank view, and the right is the layer processing view after bonding).
[0036] Figure 6 for Figure 3 Schematic diagram of the decomposition of the middle layer block 1, from left to right are strip block 1, strip block 2, and strip block 3.
[0037] Figure 7 It is a schematic diagram of the decomposition of strip block 1 (left picture) and strip block 2 (left picture) in layered block 1.
[0038] Among them, 1—layered block 1, 2—layered block 2, 3—layered block 3, 4—layered block 4, 5—layered block 5, 6—layered block 6, 7—layered block 7, 8—layered block 8, 9—layered block 9, 10—strip block 1, 11—strip block 2, 12—strip block 3, 13—strip block 4, 14—strip block 5, 15—standard block 1, 16—standard block 2, 17—standard block 3. DETAILED DESCRIPTION
[0039] The implementation of the method of the present invention is described in detail below with reference to the accompanying drawings.
[0040] A lightweight solid buoyancy material component, which realizes low-stress bonding by splicing structure design and reducing bonding area. The specific steps can be partially referred to in Figure 1 .
[0041] The solid buoyancy material standard block used in the specific embodiment is a TIPC-650 solid buoyancy material standard block produced by the Technical Institute of Physics and Chemistry of the Chinese Academy of Sciences. The density of this material is 0.63-0.65 g / cm 3 The specifications are length 400±5mm, width 300±5mm, and height 100±5mm.
[0042] The lightweight solid buoyancy material component formed by the specific embodiment is as follows Figure 2 As shown, its size is 770mm long, 570mm wide and 828mm high.
[0043] The main steps include:
[0044] Step 1: Lightweight solid buoyancy material component splicing structure design, according to the assembly relationship and installation point ( Figure 2 The top view shows the position of the lifting lugs). According to the splicing principle, the splicing layer direction is perpendicular to the lifting lug direction, and the layers are layered in the height 828 direction. According to the standard block specification height 100±5mm requirement, this component is divided into 9 layers, such as Figure 3 As shown, the design is layered blocks 1 to 9.
[0045] According to the principle of sufficient processing allowance, 5 to 10 mm is left as the allowance on one side of the component. The component shape is designed to be 790 mm long, 590 mm wide and 838 mm high. According to calculations, 4 standard blocks are required for each layer, with a total of 9 layers. The component requires 36 standard blocks.
[0046] According to the staggered principle, the standard block 100 (height) x 300 (width) x 400 (length) is first cut into standard blocks of different specifications such as 100 (height) x 150 (width) x 200 (length), 100 (height) x 300 (width) x 200 (length), 100 (height) x 150 (width) x 400 (length); then Figure 4 , Figure 5As shown in the figure, staggered seams are designed according to Figure 6 As shown, Figure 6 In the layer block decomposition diagram, two standard blocks 1 with serial number 15 and one standard block 3 with serial number 17 are combined into a strip block, and two standard blocks 2 with serial number 16 are combined into another strip block, which are then combined to form a layer block 1. Figure 4 The layered block 2 is synthesized by a similar staggered method; the entire component is as follows Figure 3 As shown, the layered blocks 1, 3, 5, 7, 9 are one combination, and the layered blocks 2, 4, 6, 8 are another combination, and the entire structure is combined to form a staggered structure.
[0047] Step 2: Standard block screening: TIPC-650 solid buoyancy material density is between 0.63 and 0.65 g / cm 3 Within the range, 36 standardized densities are screened during material cutting to ensure that the same layered blocks (such as Figure 4 The standard block selected (as shown) Figure 7 The density of the serial numbers 15, 16, and 17 shown is consistent, and the density fluctuation range is ±0.005g / cm 3 Within, and number the selected standard blocks to ensure that there is no confusion in the subsequent processing steps. Pay attention to the continuity of the numbering in the subsequent steps.
[0048] Step 3: For standard blocks (such as Figure 7 Sequence number 16) and divided into small blocks (such as Figure 7 The bonding surface of No. 15, 17) is processed by a milling machine. During processing, the roughness is controlled at Ra12.5 to improve the viscosity strength.
[0049] Step 4: After cleaning, apply A51 adhesive to the bonding surface of the standard block and small block processed in step 3 and bond them into strips (such as Figure 6 A51 adhesive is prepared from 100 parts of epoxy resin, 20-25 parts of low molecular weight polyamide curing agent, 2 parts of accelerator and 50 parts of hollow glass microspheres.
[0050] Step 5: Use a milling machine to process the bonding surface of the strip block. During processing, the roughness is controlled at Ra12.5 to improve the viscosity strength.
[0051] Step 6: After cleaning the strip blocks processed in step 5, apply A51 adhesive to the bonding surface and bond them into layered blocks (such as Figure 4 , Figure 5 shown).
[0052] Step 7. Design of the bonding area of the layered blocks. According to the requirements of the lifting position, the two ends of the lifting ears are designed as bonding surfaces, and the rest of the parts are not bonded. The size of the bonding area is determined. The design bonding area is 100mm wide and 570mm long. The width of the bonding area is 100mm, which is consistent with the thickness of the standard block of TIPC-650 solid buoyancy material; the length of the bonding area is 570mm, which is consistent with the width of the component 570mm.
[0053] Since the tensile strength of the A51 adhesive used in this embodiment is about 30MPa, considering the influence of various bonding factors, the tensile strength safety factor of the A51 adhesive is taken as 3 during calculation, and the tensile strength of the A51 adhesive is about 30 / 3=10MPa; after calculation, the maximum weight of the component is about 300kg; according to the load-bearing capacity of the designed bonding area, it is 5 to 10 times of the dead weight, and 10 times is taken for calculation, then the load is 30000N. Considering the safety factor, a single-point lifting situation may occur, and one lifting point is taken during calculation. After calculation, the bonding area is about: s=f / p=30000 / 10000000=0.003m 2 The designed bonding area is 100 mm wide and 570 mm long. The actual bonding area is calculated to be: 0.57 × 0.1 = 0.057 m 2 ; Far greater than the calculated bonding area of 0.003m 2 ; The bonding strength is sufficient and does not affect the lifting and installation of the components.
[0054] The bonding gap design between the layered blocks, such as Figure 4 As shown, the middle part of the layered block 1 is concave by 2.5 mm. Figure 5 As shown, one side of the layered block 2 is convex by 2 mm, and the middle part of the other side is concave by 2.5 mm. Figure 2 As shown, the 2mm protruding part of the layered block 2 matches the 2.5mm concave part of the middle part of the layered block 1, forming a 0.5mm gap. The other side of the layered block 2 matches the 2mm protruding part of the layered block 3, forming a 0.5mm gap. And so on, Figure 2 As shown, a gap of 0.5 mm is formed between layers of the entire component from layer block 1 to layer block 9.
[0055] The layered blocks are processed using a CNC milling machine. During processing, the roughness of the bonding surface is controlled within Ra12.5 and the flatness is controlled within 0.2 to improve the viscosity strength.
[0056] Step 8: After cleaning the layered block processed in step 7, apply a two-component epoxy adhesive to the bonding surface. Figure 3 Butt bonding is performed to form a lightweight solid buoyancy material component blank.
[0057] Subsequently, the lightweight solid buoyancy material component blank is subjected to CNC machining to achieve the required shape and size of the lightweight solid buoyancy material component through machining, that is, Figure 2 The components shown.
[0058] Figure 2 The lightweight solid buoyancy material component shown in the figure was subjected to a load test of 4 times its own weight, and was lifted three times, each time for 5 minutes, and the lugs and bonding parts were intact. Then the component was subjected to a 115MPa water pressure test in an autoclave, and all indicators were qualified as shown in Table 1.
[0059] Table 1 Completion of indicators
[0060]
[0061] Since then, a low-stress bonding process for lightweight solid buoyancy material components has been completed.
[0062] Although the present invention has been described in detail above with general descriptions and specific embodiments, it is obvious to those skilled in the art that some modifications or improvements may be made thereto based on the present invention. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of protection claimed by the present invention.
Claims
1. A low-stress bonding method for lightweight solid buoyancy material components, characterized in that: The following steps are involved: 1) Prepare block-shaped solid buoyancy materials of the same height; 2) Using block-shaped solid buoyancy materials as basic units, splicing and bonding them along a straight line to prepare strip-shaped solid buoyancy materials; 3) Using strip-shaped solid buoyancy materials as basic units, splicing and bonding them along a plane to prepare a layered solid buoyancy material; 4) Taking the layered solid buoyancy material as the basic unit, adhesive tapes are respectively arranged at both ends of the length direction or the width direction, and the upper and lower parts are spliced and bonded to prepare a lightweight solid buoyancy material component blank; the bonding length of the adhesive tape is the length or width of the layered solid buoyancy material, and the bonding width is the height of the block solid buoyancy material.
2. The low-stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: There is a joint gap of 0.5 to 1 mm between upper and lower adjacent layered solid buoyancy materials.
3. The low-stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: The bonding parts between the upper and lower adjacent layered solid buoyancy materials are arranged at positions close to the installation points or hoisting points of the lightweight solid buoyancy material components.
4. The low stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: The layered solid buoyancy material is perpendicular to an installation direction or a hoisting direction of the solid buoyancy material component.
5. The low stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: The density difference between the bulk solid buoyancy materials contained in each layer of solid buoyancy material is within 0.01g / cm 3 the following.
6. The low-stress bonding method for lightweight solid buoyancy material components according to claim 5, characterized in that: In the lightweight solid buoyancy material component, the density difference between the block solid buoyancy materials contained is within 0.01 g / cm 3 the following.
7. The low stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: Adjacent strip-shaped solid buoyancy materials are connected with staggered seams; adjacent layered solid buoyancy materials are connected with staggered seams; the staggered seam distance is not less than 50mm.
8. The low stress bonding method for lightweight solid buoyancy material components according to claim 1 or 2, characterized in that: The following steps are also included: 5) External shaping is performed on the lightweight solid buoyancy material component blank to obtain the lightweight solid buoyancy material component.