High-precision and low-cost carbon fiber type panel forming method

Abstract

The invention discloses a high-precision and low-cost carbon fiber type panel forming method which comprises the following steps: forming a single metal plate into a spherical / aspheric metal plate by means of mechanical stamping, vacuum negative pressure and the like, carrying out carbon fiber laying and bonding on the convex surface of the spherical / aspheric metal plate, then placing a preformed honeycomb core, and carrying out high-precision and low-cost carbon fiber type panel forming. Carbon fiber laying is conducted on the back of the honeycomb core again, curing forming of a carbon fiber panel is conducted in a negative pressure mode, and finally secondary finish machining is conducted on the spherical / aspheric metal plate in a machine tool polishing machining mode. According to the invention, the lightweight structure of the carbon fiber antenna panel is innovated, the advantages of high precision and long service life of metal panel processing are combined, and the difficulty in combination of the carbon fiber laying structure and the metal panel is solved. According to the method, random influence on the surface shape caused by laying of the carbon fiber layer and spraying of the metal powder can be effectively avoided, the maintainability of the carbon fiber panel is improved, and the service life of the working surface is prolonged.

Description

Technical Field

[0001] The invention relates to a forming process and method of a high-precision, low-cost carbon fiber type panel, belonging to the field of radio telescopes and radio antennas. Background Art

[0002] In recent years, significant progress has been made in the fields of radio astronomy and deep space exploration, and the performance of radio telescopes has been continuously improved. In order to meet the wide range of observation needs from meter waves, centimeter waves to millimeter waves, and even submillimeter waves, the mirror accuracy requirements of radio telescopes are increasing. In order to improve the contradiction between the production and transportation costs of high-precision mirrors, the mainstream at home and abroad currently adopts a radio telescope mirror structure composed of multiple single panels to reduce production and transportation costs. The mirror panel must have extremely high surface accuracy to meet the working requirements of radio telescopes in high frequency bands such as centimeter waves, millimeter waves and submillimeter waves. The accuracy of the reflecting surface is an important indicator to characterize the accuracy of the antenna. The accuracy of the radio telescope mirror is generally required to reach 1 / 15 of the working wavelength, and the accuracy of the mirror panel must reach 1 / 45 of the working wavelength. The design and forming method of the mirror panel are the key factors restricting the performance of the mirror of a large-aperture telescope.

[0003] If a pure metal panel is used as the main body of the antenna panel, the accuracy of the antenna working surface can be greatly improved and a sufficiently long service life can be ensured through modern high-precision machine tool processing. However, this method also greatly increases the weight of the antenna, which will bring greater challenges to the telescope's load-bearing and control aspects.

[0004] Due to the inevitable heavy weight of pure metal panels as antenna panels, some lightweight structures are being proposed in recent years. At present, there is a relatively mature high-precision carbon fiber antenna panel technology, which is mainly composed of honeycomb core + carbon fiber skin composite molding in an autoclave. The molding process of this honeycomb sandwich panel is as follows: first, the honeycomb structure is preformed through a first mold with a specific curvature, and then the first carbon fiber cloth layer is laid on a high-precision second mold, and then the preformed honeycomb is placed on the first carbon fiber cloth layer, and then the second carbon fiber cloth layer is laid on the other side of the honeycomb, and finally placed in an autoclave or a specific mold for finalization, and finally the metallization of the antenna panel is completed by spraying metal powder. The honeycomb material is generally aluminum honeycomb, stainless steel honeycomb or other non-metallic honeycomb materials. This method has high strength, high rigidity and light weight.

[0005] However, the working surface accuracy of the antenna panel produced by this process is heavily dependent on: the accuracy of the second mold for laying the first carbon fiber cloth layer, the accuracy of laying the carbon fiber cloth layer, the accuracy of spraying metal powder, etc. According to the existing processing conditions, the cost of improving mold accuracy is relatively high; the accuracy of laying the carbon fiber cloth layer and spraying the metal powder is random, and the use of metal powder as the working surface will result in a certain limitation on the service life of the antenna panel, and the risk of metal powder falling off is relatively high. Therefore, it is difficult to improve the accuracy of the carbon fiber antenna panel produced by this process. Summary of the invention

[0006] In view of the shortcomings of the prior art, the present invention provides a high-precision and low-cost carbon fiber panel forming method.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A high-precision and low-cost carbon fiber panel forming method includes the following method:

[0009] Step 1: Design and calculate the optimal curvature radius of a single reflective panel, use the optimal curvature radius to make a mold, and form the metal panel as a reflective surface into a spherical / aspherical metal panel on the mold through mechanical stamping and vacuum negative pressure;

[0010] Step 2: Cover the outer curved surface of the spherical / aspherical metal panel processed in step 1 with carbon fiber layers to form a carbon fiber front panel;

[0011] Step 3: According to the curvature radius of the outer curved surface of the spherical / aspherical metal panel, a mold of the honeycomb core is made, a flat honeycomb core is mechanically punched into a spherical / aspherical honeycomb core, and the honeycomb core is placed on the carbon fiber front panel;

[0012] Step 4: Cover the outer curved surface of the completed honeycomb core with carbon fiber layers to form a carbon fiber backplane;

[0013] Step 5: After the carbon fiber plies are bonded and cooled, the panels are bonded and solidified into one piece using a vacuum negative pressure device;

[0014] Step 6: Use high-precision machine tool polishing to grind the reflective surface and perform secondary finishing on the inner curved surface of the spherical / aspherical metal panel.

[0015] Furthermore, the high-precision and low-cost carbon fiber panel formed by the method includes a spherical / aspherical metal panel, a carbon fiber front panel, a hyperbolic honeycomb core, and a carbon fiber back panel in sequence.

[0016] Furthermore, the high-precision and low-cost carbon fiber panel has the advantages of light weight, high-precision processing of metal panels, and long service life, thereby achieving an effective combination of the carbon fiber layup structure and the metal panel.

[0017] Furthermore, when the layers are laid and covered in step 2 and step 4, glue is used to bond the layers together.

[0018] Furthermore, in step five, the vacuum negative pressure equipment is a vacuum negative pressure machine.

[0019] Furthermore, in step six, a fixing fixture is used to fix the spherical / aspherical metal panel before secondary finishing.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention provides a high-precision and low-cost carbon fiber panel forming method. This method not only innovates the lightweight structure of the carbon fiber antenna panel, but also combines the advantages of high precision and long service life of metal panel processing, solving the difficulty of combining the carbon fiber ply structure with the metal panel. This method utilizes advanced and mature high-precision machine tool polishing technology, and uses a spherical / aspherical metal plate of a certain thickness as the working surface of the carbon fiber antenna panel, replacing the previous metallization process using thin aluminum foil or spraying metal powder, and uses a high-precision machine tool to secondary process the spherical / aspherical metal plate of the carbon fiber panel, reducing the cost of improving mold accuracy, effectively avoiding the random influence of laying carbon fiber layers and spraying metal powder on the surface shape, and improving the maintainability of the carbon fiber panel and the service life of the working surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the structure of the carbon fiber reflective panel in the present invention.

[0023] Figure 2 It is a schematic diagram of the forming process of spherical / aspherical metal panels.

[0024] Figure 3 It is a schematic diagram of the reflective surface of a metal plate polished by a high-precision machine tool.

[0025] Figure 4 It is a flow chart of a method for forming a carbon fiber reflective panel.

[0026] Markings in the figure: 1-carbon fiber back panel; 2-metal honeycomb core; 3-carbon fiber front panel; 4-spherical / aspherical metal panel. DETAILED DESCRIPTION

[0027] The present invention will be further described in detail below in conjunction with the accompanying drawings.

[0028] The present invention discloses a high-precision and low-cost carbon fiber panel forming method, comprising the following steps: according to the curvature requirements of the radio telescope mirror panel, after the telescope overall panel is divided into blocks, the curvature radius of a single reflective panel is calculated. According to the curvature radius of the panel, a mold is made, and a metal flat plate with a certain thickness is formed into a spherical / aspherical metal plate by mechanical stamping, vacuum negative pressure, etc., and the spherical / aspherical metal plate is used as the working surface of the carbon fiber antenna panel. In the above steps, the convex surface of the preformed spherical / aspherical metal plate is bonded with carbon fiber ply, and then the preformed honeycomb core is placed after the carbon fiber ply is completed, and the carbon fiber ply is again performed on the back of the honeycomb core, and the layers are bonded by glue, and finally the carbon fiber panel is cured and formed by a pressure device. After the formed carbon fiber panel is cooled, the spherical / aspherical metal plate in the above-mentioned formed panel is subjected to secondary finishing by a high-precision machine tool, so as to improve the surface shape accuracy of the carbon fiber panel.

[0029] The final formation is Figure 1 The carbon fiber reflective panel structure shown includes a spherical / aspherical metal panel 4, a carbon fiber front panel 3, a hyperbolic metal honeycomb core 2, and a carbon fiber back panel 1 in sequence.

[0030] The process of the high-precision and low-cost carbon fiber panel forming method of this embodiment is as follows: Figure 4 As shown, the following steps are included:

[0031] Step 1: Design and calculate the optimal radius of curvature of a single reflective panel of a radio telescope, use the radius of curvature to make a mold, and form the metal panel as the reflective surface into a spherical / aspherical metal panel on the mold through mechanical stamping and vacuum negative pressure. Figure 2 Schematic diagram of the formation of a single reflective panel.

[0032] Step 2: Cover the outer curved surface of the spherical / aspherical metal panel processed in step 1 with carbon fiber layers, and bond the layers with glue to form a carbon fiber front panel.

[0033] Step 3: According to the curvature radius of the outer surface of the spherical / aspherical metal panel, a mold of the honeycomb core is made, a flat honeycomb core is mechanically stamped into a spherical / aspherical honeycomb core, and the honeycomb core is placed on the carbon fiber front panel.

[0034] Step 4: Cover the outer curved surface of the completed honeycomb core with carbon fiber layers, and bond the layers with glue to form a carbon fiber backboard.

[0035] Step 5: After the carbon fiber plies are bonded and cooled, the vacuum negative pressure machine is used to draw a vacuum so that each panel is attached and solidified into one. At this point, the formation of the carbon fiber reflective panel is completed. The schematic diagram of the reflective panel is as follows Figure 1shown.

[0036] Step 6: Finish the inner surface of the spherical / aspherical metal panel. Before processing, you need to design and process a set of fixed tooling, such as Figure 3 This is a schematic diagram of a fixed tooling. The reflective surface is then polished using a high-precision machine tool, which can greatly improve the surface quality and surface accuracy of the reflective surface.

[0037] In summary, the present invention is a high-precision and low-cost carbon fiber panel forming method, which combines a spherical / aspherical metal panel, a carbon fiber front panel, a hyperbolic honeycomb core, and a carbon fiber back panel into a carbon fiber reflective panel, adopts advanced and mature high-precision machine tool polishing processing technology, improves the surface shape accuracy of the metal panel as a working surface, and its sufficient thickness also prolongs its service life; the carbon fiber is formed into a panel surface by a layering method, and the honeycomb core is preformed by mold stamping. The method mainly has the advantages of high precision, low cost, and long service life.

[0038] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modification, equivalent replacement and improvement made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A high-precision and low-cost carbon fiber panel forming method, characterized in that: The following methods are included: Step 1: Design and calculate the optimal curvature radius of a single reflective panel, use the optimal curvature radius to make a mold, and form the metal panel as a reflective surface into a spherical / aspherical metal panel on the mold through mechanical stamping and vacuum negative pressure; Step 2: Cover the outer curved surface of the spherical / aspherical metal panel processed in step 1 with carbon fiber layers to form a carbon fiber front panel; Step 3: According to the curvature radius of the outer curved surface of the spherical / aspherical metal panel, a mold of the honeycomb core is made, a flat honeycomb core is mechanically punched into a spherical / aspherical honeycomb core, and the honeycomb core is placed on the carbon fiber front panel; Step 4: Cover the outer curved surface of the completed honeycomb core with carbon fiber layers to form a carbon fiber backplane; Step 5: After the carbon fiber plies are bonded and cooled, the panels are bonded and solidified into one piece using a vacuum negative pressure device; Step 6: Use high-precision machine tool polishing to grind the reflective surface and perform secondary finishing on the inner curved surface of the spherical / aspherical metal panel.

2. A high-precision and low-cost carbon fiber panel forming method according to claim 1, characterized in that: The high-precision and low-cost carbon fiber panel formed by the method comprises a spherical / aspherical metal panel, a carbon fiber front panel, a metal honeycomb core and a carbon fiber back panel in sequence.

3. A high-precision and low-cost carbon fiber panel forming method according to claim 1, characterized in that: The high-precision and low-cost carbon fiber panel has the advantages of light weight, high-precision processing of metal panels, and long service life, and realizes the effective combination of carbon fiber layup structure and metal panels.

4. A high-precision and low-cost carbon fiber panel forming method according to claim 1, characterized in that: When the layers are laid and covered in step 2 and step 4, glue is used to bond the layers together.

5. A high-precision and low-cost carbon fiber panel forming method according to claim 1, characterized in that: In step five, the vacuum negative pressure equipment is a vacuum negative pressure machine.

6. A high-precision and low-cost carbon fiber panel forming method according to claim 1, characterized in that: In step six, a fixing fixture is used to fix the spherical / aspherical metal panel before secondary finishing.

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