Manufacturing method of composite material box-shaped beam with closed-angle end part

Abstract

The invention belongs to the field of composite material manufacturing, and relates to a manufacturing method of a composite material box-shaped beam with closed-angle ends. The composite material cover plate of the composite material box-shaped beam can be manufactured, and the structural form of the composite material cover plate can well act on curing forming of the composite material box-shaped beam. According to the invention, the manufacturing of the composite material box-shaped beam, the inspection of the axial direction size, the inspection of the profile size and the like can be realized. The invention innovatively provides a metal joint structure to replace a commonly used metal hinge support arm, and the metal joint structure has a function of measuring the profile precision of the inner profile of the edge strip of the composite box-shaped beam. The invention innovatively provides a split combined type forming tool and a measuring tool, and realizes a manufacturing process method of the composite material box-shaped beam with the closed angle at the end part. The measuring tool is innovatively provided, the measuring tool can measure the axial direction size of the composite material box-shaped beam, and the measuring range is large.

Description

Technical Field

[0001] The invention belongs to the field of composite material manufacturing, and relates to a method for manufacturing a composite material box beam with a closed angle at the end. Background Art

[0002] Different from the requirement of demoulding slope>0° ​​in the structural design of general composite parts, for structural design and functionality considerations, the composite box beam of the present invention is designed with an angle of less than 90° between at least one end and the web surface, i.e., a closed angle design. For a composite box beam with a closed angle at the end, according to the general demoulding process, it is pushed and demoulded from the smaller width part (small end) to the larger width part (large end). However, the composite box beam has a variable thickness sunken area design, and the composite box beam after curing has poor toughness. If the composite box beam is pushed and demoulded from the smaller width part (small end) to the larger width part (large end), it is very easy to cause damage to the composite box beam or even scrap it.

[0003] Taking the composite box beam as an example, if the material of the forming tooling is ordinary steel, the difference between the expansion coefficient of the forming tooling and the expansion coefficient of the composite box beam needs to be considered, and a certain process compensation needs to be made on the forming surface of the forming tooling along the axial dimension of the composite box beam, such as a certain inward shrinkage of the forming surface along the axial dimension of the composite box beam; if the material of the forming tooling is invar36 steel, the expansion coefficient of the forming tooling is close to the expansion coefficient of the composite box beam, but there are still differences. For the slender composite box beam, the forming tooling manufactured according to the inner surface of the composite box beam will also have dimensional deviation in the axial dimension of the composite box beam after forming. The curing and forming process of composite parts is an extremely complex coupling process of time, temperature and pressure. Whether it is using software simulation analysis or manufacturing based on experience, technicians need to repair the forming tooling based on the actual axial dimension of the composite box beam. Especially in the development stage of the composite box beam, it is necessary to repeatedly repair the forming tooling to ensure that the actual axial dimension of the composite box beam meets the engineering requirements.

[0004] After the composite box beam is solidified, the axial dimension of the composite box beam is measured by a measuring tool such as a steel ruler or a caliper. Due to the lack of a suitable measurement reference, the measured axial dimension data is not accurate, and the composite box beam with a large axial dimension that exceeds the measuring range of the measuring tool cannot be measured. If the axial dimension of the composite box beam is measured by a forming tool, the composite box beam is positioned on the forming surface of the forming die according to the shape surface, and the gap value data between the composite box beam and the forming surface of the forming die is measured by a feeler gauge to indirectly obtain the axial dimension of the composite box beam. This measurement scheme can only evaluate the axial dimension of the composite box beam on the side of the tooling surface, and cannot evaluate the axial dimension of the composite box beam on the side of the bag surface. According to the general method for measuring the surface accuracy of composite parts after molding, after the composite box beam is solidified and formed, it is generally necessary to return to the molding tool to check the mold gap, that is, use a feeler gauge to measure the gap value between the composite box beam surface and the molding tool. However, the visibility of the feeler gauge inspection is poor, that is, there is uncertainty in the inspection area and inspection depth, and the feeler gauge can only measure the gap value between the edge strip surface of the composite box beam and the molding tool, and the feeler gauge cannot measure the gap value between the web surface of the composite box beam and the molding tool. Obviously, according to the general method for measuring the surface accuracy of composite parts after molding, it is impossible to effectively and accurately measure the surface accuracy of the inner surface of the composite box beam.

[0005] In view of the above problems, the present invention takes a manufacturing method of a composite box beam with a closed angle at the end as the research object, and creatively proposes a molding tool and a method of using the composite box beam. The molding tool and the method of using can solve the molding and demoulding problems of the composite box beam with a closed angle at the end. The molding tool has the characteristics of low difficulty of rework and short rework cycle, and is suitable for the manufacturing method that needs to continuously correct the axial dimension of the composite box beam. Creatively propose a measuring tool and a method of using that can measure the axial dimension of the bag surface side of the composite box beam online. The measurement range is within the deviation of -5-5mm of the actual axial dimension of the composite box beam relative to the axial dimension. The measurement accuracy of the axial dimension is 0.01mm, which fully meets the manufacturing requirements of the composite box beam. Creatively propose a metal joint, which is simplified on the basis of retaining the main function of the metal hinge arm, and the metal structure has the function of measuring the surface accuracy of the inner surface of the edge strip of the composite box beam. Summary of the invention

[0006] The purpose of this patent is to invent a method for manufacturing a composite box beam with a closed angle at the end. The manufacturing method involves a composite box beam forming tool, a composite cover plate forming tool, a measuring tool and a method for using the tool.

[0007] The technical solution of the present invention is as follows:

[0008] A method for manufacturing a composite material box beam with a closed angle at the end thereof, the manufacturing method involving a composite material box beam forming tool, a composite material cover plate forming tool, a measuring tool and a method for using the tool.

[0009] 1) Composite material box beam forming tooling

[0010] The composite material box beam forming tooling adopts a male mold frame structure design as a whole. The tooling material is made of Invar36 steel with an expansion coefficient close to that of the composite material parts. The tooling forming surface is extracted according to the theoretical inner surface of the composite material box beam, and the tooling forming surface thickness is 10-20mm.

[0011] The composite material box beam forming tool adopts a combined structural design of a fixed carcass, a removable carcass and a removable base. The removable carcass is combined with the fixed carcass through the removable base and matched through the mating surface. The removable base is fixed to the tooling pallet in the form of a combination of screws and pins. The removable carcass and the removable base are matched in surface-to-surface contact, such as the side of the removable carcass contacts the side of the removable base, and the bottom of the removable carcass contacts the mating surface of the removable base, to ensure the combination accuracy of the fixed carcass and the removable carcass.

[0012] The detachable base is designed with threaded holes for lifting rings and is equipped with lifting rings. The purpose of designing the lifting rings is to use the pulling force generated by the tractor on the production site to separate the detachable base from the initial position and slide laterally after the composite material box beam is solidified and formed. After the detachable base slides, space is given to the detachable carcass to descend, that is, the detachable carcass is removed from the composite material box beam, and then the composite material box beam is demoulded.

[0013] The margin of the composite material box beam forming tooling at the composite material box beam edge strip is designed according to the extension of the theoretical edge strip boundary by 40-60mm.

[0014] 2) Composite cover plate forming tooling

[0015] The composite cover plate forming tooling is made of Invar36 steel with a similar expansion coefficient to the composite cover plate. The tooling forming surface is manufactured with the outer surface of the pocket side of the composite material box beam as the extraction surface. The composite cover plate forming tooling adopts a positive mold frame structure design.

[0016] The composite cover plate forming tooling consists of two parts. One part is the closed angle part of the formed composite cover plate, namely the forming tooling 13-1, considering that the composite cover plate and the composite material box beam face the same demoulding problem in the closed angle part; the other part is the non-closed angle part of the formed composite cover plate, namely the forming tooling 13-2.

[0017] The forming surface of the composite cover plate forming tooling is manufactured and inspected with a negative difference of -0.1 to -0.2mm on the outer surface of the composite material box beam with a pocket surface side. The purpose is to ensure that when the composite cover plate acts on the composite material box beam, it can form a certain extrusion pressure on the blank of the composite material box beam, fully eliminate the air gap wrapped in the process of stacking the blank layers, and ensure the internal forming quality of the composite material box beam, especially control the void content of the R corner area of ​​the composite material box beam. At the same time, the composite cover plate forming tooling is offset H (5-10mm) based on the plane of the tooling support plate to make a boss working surface. The length of the boss is the same as the length of the composite cover plate, and the width of the boss is greater than the width L of the "skirt". The edge has a structural design similar to the "skirt", and the width of the "skirt" L = 10-20mm. The structural design of the "skirt" on the edge of the composite cover plate has two purposes: one is that the "skirt" can be used as a prying edge after the composite cover plate is demoulded; the other is that when the composite material box beam is cured and packaged, the vacuum nozzle is arranged on the tooling pallet, and the vacuum negative pressure under the vacuum bag packaging acts on the "skirt" of the composite cover plate, and then the "skirt" promotes the bonding effect of the composite cover plate on the composite material box beam blank.

[0018] 3) Measuring tooling

[0019] The measuring tool is composed of five parts: a metal joint part, a part for positioning the metal joint part, an adjustable end part, a fixed end part, and a flange shape surface clamping plate part.

[0020] The overall structure of the measuring tool is as follows: Figure 7 , Figure 8 , including metal joint parts, platforms, brackets, connecting components, columns, tensioner supports, tensioners, pins, connectors, supports, 0.1mm thick metal gaskets, end action ends, placeholders, beam end adjustable ends, end action ends, dial indicators, slotted screw rods, handle nut, T-key, sleeve, raised block, long positioning pin, table seat, beam end fixed end, edge strip profile clamp, support plate, L-shaped support, and tensioner sleeve.

[0021] 3.1) The structural schematic diagram of the metal joint part is shown in FIG6 , which is mainly composed of a working surface on the web surface side and a working surface on the flange surface side.

[0022] The metal joint part extracts the metal hinge arm used for docking with the aircraft body structure in the composite rudder box section, simplifies the metal hinge arm, retains the central axis position of the intersection of the metal hinge arm and designs it into a diameter with it as the center. The metal joint part is made of Invar steel, and its expansion coefficient is close to that of the composite box beam.

[0023] In order to reduce the deadweight of the metal joint part, remove the driven shaft of the metal hinge arm and unnecessary structures, the metal joint part mainly retains the working surface, reinforced ribs, positioning pin holes and other parts. The length of the working surface of the metal joint part along the axial direction of the composite box beam is designed to be 150-200mm. The working surface of the metal joint part located on the web surface side of the composite box beam is offset 2mm to the inner surface of the composite box beam according to the theoretical position, that is, there is a theoretical gap of 2mm between the working surface on the web surface side and the web surface of the composite box beam; the working surface of the metal joint part located on the edge strip surface side of the composite box beam is offset 0.5mm to the inner surface of the composite box beam according to the theoretical position, that is, there is a theoretical gap of 0.5mm between the working surface on the edge strip surface side and the edge strip surface of the composite box beam.

[0024] The working surface on the web surface side and the working surface on the flange surface side are offset and manufactured according to the theoretical position on the web surface and flange surface of the composite material box beam. The purpose is to measure the flange surface deformation of the composite material box beam with a feeler gauge between the flange surface side of the composite material box beam where the surface deformation is easy to occur and the working surface on the flange surface side of the metal joint.

[0025] 3.2) The partial structural diagram of the positioning metal joint part is shown in Figure 7 , Figure 8 , Fig. 9 , mainly composed of components such as platforms and connection components.

[0026] The platform height is between 1200mm and 1400mm, so that the operator can perform assembly work in a standing position.

[0027] The connecting assembly is mainly composed of columns, tensioner supports, tensioners, connecting parts, supports and other components.

[0028] The column is fixed on the platform by a mechanical connection method combining screws and pins, and the support is fixed on the column by a mechanical connection method combining screws and pins.

[0029] The connector is fixed on the support by a positioning pin. Two pin holes are designed on the connector and arranged alternately. The connector can be connected and fixed to the metal joint part by a metal positioning pin through the pin hole.

[0030] See the schematic diagram of the structure where the tensioner is located. Figure 7 The main body of the tensioner support is a cylindrical design with a through hole design inside. Both ends of the tensioner support have flange structure designs. The flange structure on one side is fixed to the platform by a mechanical connection method combining screws and pins, and the flange structure on the other side is connected and fixed to the tensioner sleeve by a mechanical connection method combining screws and pins. The tensioner sleeve adopts a semicircular annular groove design.

[0031] The handle nut adopts a boss structure design on the outside and a threaded hole design on the inside. The handle nut cooperates with the semicircular annular groove of the tensioner sleeve through its own boss structure. The handle nut and the tensioner sleeve adopt a clearance fit to ensure that the handle nut can rotate around its own axis.

[0032] The handle nut is designed with a threaded hole. The main body of the tensioner is designed with a threaded rod. The tensioner and the handle nut are screwed together. The tensioner is driven to move along its own axis by rotating the handle nut. The outer diameter of the tensioner is accommodated within the through hole size of the tensioner support to ensure the range of motion of the tensioner, so that the tensioner can act on the web surface of the composite box beam to maintain a clamped state, and can stay away from the web surface of the composite box beam to maintain a relaxed state to facilitate the loading and disassembly of the composite box beam.

[0033] 3.3) The structural schematic diagram of the adjustable end part is shown in Figure 10. The adjustable end of the beam end surface is mainly composed of a metal pin 28, an end surface action end, a dial indicator, a slotted screw rod, a handle nut, a T-key, a sleeve, a raised block, a positioning long pin, a gauge seat and other components.

[0034] The adjustable end of the beam end face is fixed to the column by a sleeve through a mechanical connection method combining screws and pins.

[0035] The sleeve has a through hole design inside, and one side end of the sleeve adopts a semicircular annular groove design. The top of the sleeve is designed with a raised block, which is fixed to the top of the sleeve by welding. The active surface of the raised block is the active surface of the measuring head of the dial indicator. The position of the active surface of the raised block should ensure that it is perpendicular to the movement direction of the measuring head of the dial indicator. A matching hole that cooperates with the T-key is designed on the top of the sleeve.

[0036] The handle nut adopts a boss structure design on the outside and a threaded hole design on the inside. The handle nut cooperates with the semicircular annular groove of the sleeve through its own boss structure. The handle nut and the sleeve adopt a clearance fit to ensure that the handle nut can rotate around its own axis.

[0037] The outer diameter of the slotted screw is contained within the through hole size of the sleeve to ensure that the slotted screw moves along its own axis, and the sleeve plays a role in supporting the slotted screw. The handle nut is connected to the slotted screw by screw connection.

[0038] One end of the T-key acts on the slotted screw, and the other end acts on the matching hole on the top of the sleeve that cooperates with the T-key. The purpose of the T-key is to ensure that the slotted screw moves along its own axial direction without deflection around the axial direction.

[0039] The action surface of the end action end is manufactured by extracting the end surface shape of one side of the composite material sleeve beam, and the end action end is fixed on the slotted screw rod by connecting with a metal positioning pin.

[0040] The range of the dial gauge is 0-10mm, and the graduation value is 0.01mm. The measuring rod and measuring head of the dial gauge are perpendicular to the action surface of the raised block, and the movement direction of the measuring rod and measuring head of the dial gauge should be parallel to the axis direction of the slotted screw.

[0041] The meter seat has a through hole design, and the meter seat and the slotted screw rod are in an interference fit relationship to ensure that the meter seat is fixed on the slotted screw rod and moves along the axis direction of the slotted screw rod.

[0042] The dial base has a through hole design, and the dial base and the shaft sleeve of the dial indicator are in an interference fit relationship to ensure that the dial indicator is fixed on the dial base, and the measuring rod and the measuring head of the dial indicator are in a relatively free telescopic state.

[0043] The rotation of the handle nut drives the slotted screw to move horizontally, and then drives the end face action end to move horizontally. A through hole is designed at the connection between the sleeve and the slotted screw, and the diameter of the positioning long pin is consistent with the diameter of the through hole. When the positioning long pin is inserted into the through hole of the sleeve and the slotted screw, the theoretical spacing between the action surface of the end face action end and the end surface of one side of the composite material box beam in the axial direction is 5mm, and the measuring head of the dial indicator is at the position of 10mm elongation and acts on the action surface of the raised block.

[0044] When the end face action end is in the theoretical position, pull out the long positioning pin, rotate the handle nut to drive the slotted screw to move horizontally, and then drive the end face action end to move toward the end face axis direction of the composite material sleeve beam, until the action surface of the end face action end fits with the end face of one side of the composite material box beam. At this time, the dial indicator rotation scale value a acting on the action surface of the raised block should be recorded. The actual axial size deviation of the composite material box beam is Δ=5-a. If Δ>0, the actual axial size of the composite material box beam is larger than the theoretical size; if Δ<0, the axial size of the composite material box beam is smaller than the theoretical size.

[0045] 3.4) The structural schematic diagram of the fixed end part is shown in Figure 12. The fixed end of the beam end face adopts a structural form, positioning and movement method similar to the adjustable end of the beam end face. The fixed end of the beam end face is mainly composed of an end face action end, a slotted screw rod, a handle nut, a T-key, a sleeve, a positioning long pin and other components.

[0046] The action surface of the end action end is manufactured by extracting the outer shape of the end face of the other side of the composite material box beam. The end action end is designed with a slotted position relative to the edge strips on both sides of the composite material box beam. A placeholder is placed at the slotted position. The placeholder is extracted and manufactured according to the outer shape of the edge strips on both sides of the composite material box beam. The purpose of the placeholder is to ensure that the composite material box beam is in the center position of the end action end. The end action end is fixed to the slotted screw by connecting with a metal locating pin.

[0047] The rotation of the handle nut drives the slotted screw to move horizontally, and then drives the end face action end to move horizontally. A through hole is designed at the connection between the sleeve and the slotted screw, and the diameter of the positioning long pin is consistent with the diameter of the through hole. When the positioning long pin is inserted into the through hole of the sleeve and the slotted screw, the theoretical spacing in the axial direction between the action surface of the end face action end and the end face of the other side of the composite material box beam is 0mm, that is, the theoretical position of the end face of the other side of the composite material box beam.

[0048] 3.5) The structural schematic diagram of the edge strip profile clamping plate is shown in Figure 13. The edge strip profile clamping plate is manufactured by extracting the edge strip profile of the composite material box beam and offsetting it outward by 2mm as a reference. The edge strip profile clamping plate is connected to the support plate by screws and positioning pins. The support plate is positioned and connected to the L-shaped support by screws and positioning pins, and the L-shaped support is fixed to the platform by a mechanical connection method of screws and positioning pins.

[0049] When measuring the flange profile of a composite box beam, use a feeler gauge to measure the gap between the flange profile clamp and the composite box beam flange profile. The theoretical gap value is 2 mm. The actual composite box beam flange profile deviation is converted based on the gap value measured by the feeler gauge.

[0050] If the actual gap value measured by the feeler gauge is 3mm, the actual deviation of the composite material box beam flange surface is -1mm.

[0051] If the actual gap value measured by the feeler gauge is 1mm, the actual deviation of the outer surface of the composite box beam flange is 1mm.

[0052] Advantages of the invention

[0053] (1) The present invention can realize the manufacturing of composite cover plates for composite box beams, and the structural form of the composite cover plates can better play a role in the curing and forming of composite box beams.

[0054] (2) The patent of the present invention can realize the manufacture of composite material box beams, the inspection of axial dimensions, the inspection of surface dimensions, etc.

[0055] (3) The present invention innovatively proposes a metal joint structure to replace the commonly used metal hinge arm. The metal joint structure has the function of measuring the surface accuracy of the inner surface of the edge strip of the composite box beam.

[0056] (4) The patent of this invention innovatively proposes a split combined forming tool and a measuring tool, realizing a manufacturing process method for a composite material box beam with a closed angle at the end.

[0057] (5) The present invention innovatively proposes a measuring tool, which can measure the axial dimension of the composite box beam. The measuring range is large, which is -5-5mm relative to the theoretical axial dimension, and the measuring accuracy is 0.01mm.

[0058] (6) The present invention innovatively proposes a split modular forming tooling, which has the characteristics of low difficulty in rework and short rework cycle, and is suitable for a manufacturing method that requires continuous correction of the axial dimension of a composite material box beam. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 Schematic diagram of composite material box beam forming tooling;

[0060] Figure 2 Schematic diagram of composite cover plate forming tooling;

[0061] Figure 3 Schematic diagram of the molding structure of the composite cover plate;

[0062] Figure 4 Schematic diagram of the composite cover acting on the blank of the composite box beam and the composite cover butt joint;

[0063] Figure 5 Schematic diagram of the metal hinge arm structure;

[0064] Figure 6 (a) Schematic diagram of the metal joint structure;

[0065] Figure 6(b) is a schematic diagram of the central axis of the intersection of the gold metal hinge arms;

[0066] Figure 7 Measuring tooling top view;

[0067] Figure 8 Partial front view of the measuring tool;

[0068] Fig. 9 Schematic diagram of the metal joint positioning part of the measuring tool;

[0069] Fig. 10(a) is a perspective view of the adjustable end portion;

[0070] Fig. 10(b) is a side view of the adjustable end portion;

[0071] Figure 11 (a) is a schematic diagram of the structure where the tightener is located;

[0072] Figure 11(b) is an exploded view of the structure where the tightener is located;

[0073] Fig. 12(a) Schematic diagram of the fixed end part A;

[0074] Fig. 12(b) Schematic diagram of the fixed end portion B;

[0075] Figure 13 (a) is a front view of the edge strip profile surface of the card plate;

[0076] Figure 13(b) is a side view of the edge strip profile surface of the cardboard.

[0077] In the figure: 1 a composite material box beam forming tool; 2 a fixed carcass; 3 a removable carcass; 4 a removable base; 5 a mating surface; 6 a tooling pallet; 7 a removable carcass side; 8 a removable base side; 9 a removable carcass bottom surface; 10 a removable base mating surface; 11 a lifting ring; 12 a margin; 13 a composite cover plate forming tool; 14 a composite cover plate; 15 a "skirt"; 16 a boss; 17 a metal hinge arm; 18 a center axis of the intersection of the metal hinge arm; 19 a metal joint portion; 20 a working surface on the web surface side; 21 a working surface on the edge strip surface side; 22 a platform; 23 a bracket; 24 a connecting assembly; 25 a column; 26 a tightener support; 27 a tightener; 28 a pin; 29 a connecting piece; 30 a support; 31 0.1mm thick metal gasket; 32 end face effective end; 33 placeholder; 34 beam end face adjustable end; 35 end face effective end; 36 dial indicator; 37 slotted screw rod; 38 handle nut; 39 T-type key; 40 sleeve; 41 raised block; 42 long positioning pin; 43 seat; 44 beam end face fixed end; 45 edge strip outer surface clamp; 46 support plate; 47 L-shaped support; 48 tensioner sleeve. DETAILED DESCRIPTION

[0078] Specifically, it includes the manufacture of composite cover plates, the manufacture of composite material box beams, the measurement of the outer dimensions of composite material box beams, the repair of composite material box beam forming tooling, and the reconstruction of composite material box beams.

[0079] 1) Manufacturing of composite cover plates

[0080] 1.1) Based on the composite cover forming tool 13 (see Figure 2 ) Molded composite cover plate 14 (see Figure 3 ), the composite cover plate 14 is a mixture of rubber and plain fabric prepreg, the surface layer is rubber, the single layer thickness of the unvulcanized airpad rubber is 1.59mm, the plain fabric prepreg is arranged in the R corner area and the "skirt" area, the thickness of the single layer of the plain fabric prepreg after curing is 0.2-0.3mm, and the plain fabric prepreg is a 180±6℃ high temperature cured prepreg. The composite cover plate 14 adopts a staggered layout of plain fabric prepreg in the R corner area and the "skirt" 15 area, with a total of 4 layers of plain fabric prepreg to increase the pressure transmission effect of the R corner and the structural stiffness of the "skirt", and the layer ends of the plain fabric prepreg are staggered by 2mm.

[0081] 1.2) Curing parameters of composite cover plate: holding temperature 180±6℃; holding time 2-3h; vacuum pumping throughout the process, vacuum degree not less than -0.092MPa; curing pressure 0.6-0.7MPa; heating and cooling rate 0.5-3℃ / min.

[0082] 1.3) A certain number of holes are opened at the R corners of the manufactured composite cover plate 14, and the hole diameter is To facilitate ventilation.

[0083] 1.4) The composite cover plate forming tool 13 is designed to be composed of two parts, so the composite cover plate 14 is at least two pieces, namely the composite cover plate 14-1 and the composite cover plate 14-2. The edges of the composite cover plates 14-1 and 14-2 are chamfered, and the chamfer angle is 20-40°.

[0084] 2) Fabrication of composite box beams

[0085] 2.1) Apply a mold release agent on the molding surface of the composite material box beam molding tool 1, and lay up the layer blanks of the composite material box beam layer by layer until all the layer blanks are laid up.

[0086] 2.2) Place composite cover plates 14-1 and 14-2 outside the already laid composite box beam blank (see Figure 4 ) and perform vacuum bag packaging. A 0.1 mm thick metal gasket 31 is placed in the joint area between the composite cover plate 14-1 and the composite cover plate 14-2 (see Figure 4 ) to avoid fiber wrinkles in the joint area between the adjacent composite cover panels 14-1 and 14-2.

[0087] 2.3) Carry out autoclave curing of the composite material box beam blank. The curing parameters depend on the resin system of the prepreg. Generally, the whole process is vacuumed not less than -0.092MPa, the curing pressure is 0.6-0.8Mpa, the temperature is 215±10℃, the insulation time is 180-240min, and the heating and cooling rate does not exceed 3℃ / min.

[0088] 2.4) After the composite material box beam is solidified and formed, auxiliary materials such as vacuum bags and breathable felt are cleaned, and the composite cover plates 14-1 and 14-2 are removed.

[0089] 2.5) Use the pulling force generated by the tractor on the production site to separate the removable base 13 from the initial position and cause lateral sliding. After the removable base 13 slides, it provides space for the removable carcass 12 to fall, that is, the removable carcass 12 is removed from the composite material box beam, and the demoulding of the composite material box beam is achieved. (See Figure 1 )

[0090] 2.6) After the composite material box beam is demoulded, the shape cutting is performed, and the operator completes the shape cutting of the composite material box beam along the tire line mark of the composite material box beam.

[0091] 3) Dimensional measurement of composite box beams

[0092] The external dimension measurement of composite box beam mainly includes the measurement of the axial dimension of composite box beam and the measurement of the internal dimension of composite box beam. (See Figure 7-Figure 1 3)

[0093] 3.1) Prepare composite box beam.

[0094] 3.2) Remove the metal joint part 19 from the measuring fixture, remove the side where the connecting piece 29 is connected to the support 30, and keep the connecting piece 16 in the open state.

[0095] 3.3) The tensioner 27 is rotated to a low position, not higher than the action surface of the support plate 46, to ensure that when the composite material box beam is placed, the tensioner 14 does not interfere with the web surface of the composite material box beam.

[0096] 3.4) At the adjustable end portion, i.e., the adjustable end 34 of the beam end surface, the handle nut 38 rotates to drive the slotted screw rod 37 to move laterally, and then drives the end surface action end 35 to move laterally.

[0097] A through hole is designed at the connection between the sleeve 40 and the slotted screw 37, and the diameter of the positioning long pin 42 is consistent with the diameter of the through hole. When the positioning long pin 42 is inserted into the through hole, the initial spacing between the action surface of the end action end 35 and the end surface of one side of the composite material box beam in the axial direction is 5mm, and the measuring head of the dial indicator 36 is at a position of 10mm elongation and acts on the action surface of the protruding block 41.

[0098] 3.5) At the fixed end portion, i.e., the fixed end 44 of the beam end face, the handle nut 38 rotates to drive the slotted screw 37 to move horizontally, and then drives the end face action end 32 to move horizontally. A through hole is designed at the connection between the sleeve 40 and the slotted screw 37. The diameter of the positioning long pin 42 is consistent with the diameter of the through hole. When the positioning long pin 42 is inserted into the through hole, the action surface of the end face action end 32 is located at the theoretical zero point position of the end face of one side of the composite material box beam. A placeholder 33 is placed in the slot of the end face action end 32.

[0099] 3.6) Place the composite box beam on the measuring fixture.

[0100] 3.7) The metal joint part 19 is connected to the connecting piece 29 via a positioning pin.

[0101] 3.8) Connect the connecting piece 29 in the open state to the support 30 via the positioning pin, and keep the connecting piece 29 in the closed working state.

[0102] 3.9) Insert a process compensation gasket into the gap between the working surface 20 on the web surface side of the metal joint part 19 and the web surface. The thickness of the process compensation gasket is 2 mm.

[0103] 3.10) On the outside of the web surface of the composite material box beam, tighten the tensioner 27 to make the web surface of the composite material box beam, the metal joint part 19, the process compensation gasket, etc. fit closely. Because the action surface of the support plate 46 is 3mm lower than the theoretical web outer surface of the composite material box beam, that is, the composite material box beam with the fixed end 34 near the beam end face is placed at a position 3mm lower than the theoretical position, tightening the tensioner 27 will drive the end face of the composite material box beam near the fixed end 34 of the beam end face to rise continuously, and the end face of the composite material box beam near the fixed end 34 of the beam end face may not fit partially with the end face action end 32. It is necessary to use non-metallic tools such as rubber hammers to act on the end face of the composite material box beam to ensure that the end face of the composite material box beam fits the end face action end 32 completely, and finally reach a state where the tensioner 27 cannot be tightened.

[0104] 3.11) At the adjustable end portion, i.e., the adjustable end 34 of the beam end face, when positioned by the positioning long pin 42, the initial spacing in the axial direction between the active surface of the end face active end 35 and the end face of one side of the composite material box beam is 5 mm.

[0105] According to the comparison between the axial dimension deviation L of the composite material box beam and the initial spacing of 5mm, the rotation scale value a of the dial indicator 36 acting on the action surface of the protruding block 41 is given, a=5-L. The slotted screw 37 is driven to move horizontally by the rotation of the handle nut 38, and the handle nut 38 rotates in a unidirectional movement direction, that is, the unidirectional movement drives the end surface action end 35 to move toward the end surface axis direction of the composite material box beam, and at the same time, the dial indicator 36 acting on the action surface of the protruding block 41 rotates, and the rotation scale value a makes the action surface of the end surface action end 35 fit with the other side end surface of the composite material box beam.

[0106] If the rotation scale value a is 3mm, the axial dimension deviation L of the composite box beam is 2mm.

[0107] If the rotation scale value a is 7mm, the axial dimension deviation L of the composite box beam is -2mm.

[0108] 3.12) Use a feeler gauge to measure the gap between the inner surface of the composite box beam flange and the working surface 21 of the metal joint flange surface side, and reserve a gap value of 0.5 mm. According to the gap value measured by the feeler gauge, convert the actual composite box beam flange inner surface deviation.

[0109] If the actual gap value measured by the feeler gauge is 1mm, the actual inner surface deviation of the composite material box beam edge strip is 0.5mm.

[0110] If the actual gap value measured by the feeler gauge is 0mm, the actual inner surface deviation of the composite material box beam edge strip is -0.5mm.

[0111] 3.13) Remove the positioning pins on the metal joint part 19, withdraw the tensioner 27, remove the side of the connection between the connector 29 and the support 30, and keep the connector 29 in the open state. Pull out the positioning long pins 42 and 44 of the beam end fixed end, rotate the handle nut 38 to make the end surface action end 32 and the end surface action end 35 move laterally away from the composite material box beam, and remove the composite material box beam from the measuring fixture.

[0112] 4) Repair method of composite material box beam forming tooling

[0113] In the development stage of the composite box beam, the maturity of the relevant manufacturing technology is relatively low. After the actual axial size of the composite box beam is measured by the measuring tool, the actual size may be inconsistent with the engineering design size, and the composite box beam forming tool 1 needs to be repaired, that is, the composite box beam forming tool 1 along the axial end face of the composite box beam is repaired by removing and adding material. Since it is a combined forming tool, the difficulty of repairing the forming tool 1 of the present invention will be reduced.

[0114] The composite material box beam forming tool 1 is subjected to the repair process of removing and adding materials, and it is determined to be the repair process of removing and adding materials on the detachable carcass 3 and the detachable base 4. The detachable carcass 3 and the detachable base 4 are small in size and small in weight, and have low load-bearing and size requirements for CNC machine tools. If it is necessary to reduce the actual axial size of the composite material box beam after solidification, it is necessary to remove the material from the mating surface 5 of the detachable carcass 3. The mating surface 5 is a plane design, and the difficulty of removing the material is relatively low. The gap between the detachable carcass 3 and the limiting surface of the detachable base 4 generated by the removal of the material can be made of a single-layer stainless steel sheet with a thickness of 0.1 mm. Because the stainless steel sheet has certain advantages such as conformability and economy, different layers of stainless steel sheets are selected according to different gap values. If it is necessary to extend the actual axial size of the composite box beam after solidification, it is necessary to add material to the mating surface 5 of the detachable carcass 3. The mating surface is a flat design, and the difficulty of adding material is relatively low. You can choose to weld the invar36 raw material on the mating surface and perform CNC machine tool milling processing, or you can choose to add several layers of single-layer 0.1mm thick stainless steel sheets on the mating surface 5, and then paste them on the molding surface of the mating surface 5 area of ​​the molding tool. A single layer of 0.1 mm single-sided adhesive release cloth makes the molding surface of the molding tooling have a smooth feature. The corresponding limiting surface of the removable base 4, namely the removable base side 8 and the removable base mating surface 10, needs to be removed to avoid interference between the removable base side 8 and the removable base mating surface 10 of the removable base 4 and the removable tire body 3 when they are combined.

[0115] 5) Re-manufacture of composite box beams

[0116] Based on the repaired composite box beam forming tooling, the composite box beam is manufactured again and the outer dimensions of the composite box beam are measured again.

Claims

1. A method for manufacturing a composite box beam with closed angle ends, characterized in that: The steps are as follows: Step 1: Design of the tooling for composite box beam forming The composite material box beam forming tool adopts a combined structural design of a fixed carcass (2), a detachable carcass (3) and a detachable base (4); the detachable carcass (3) is combined with the fixed carcass (2) through the detachable base (4) and is matched through a matching surface (5); the detachable base (4) is fixed to the tool support plate (6) in the form of a combination of screws and pins, and the detachable carcass (3) and the detachable base (4) are matched in surface-to-surface contact; The margin of the composite material box beam forming tooling at the composite material box beam edge strip is designed according to the theoretical edge strip boundary extension of 40-60mm; Step 2: Design of composite cover molding tooling The molding surface of the composite cover plate molding tool (13) is manufactured and inspected with a negative difference of -0.1 to -0.2 mm on the outer surface of the composite material box beam on the side of the pocket surface. The composite cover plate molding tool (13) is offset H (5-10 mm) based on the plane of the tool support plate (6) to form a working surface of the boss (16). The length of the boss (16) is the same as the length of the composite cover plate (14), and the width of the boss (16) is greater than the width L of the "skirt" (15), L = 10-20 mm. Step 3: Measuring tooling and tooling design The measuring tool comprises a metal joint part (19), a platform (22), a bracket (23), a connecting assembly (24), a column (25), a tensioner support (26), a tensioner (27), a pin (28), a connecting piece (29), a support (30), a 0.1 mm thick metal gasket (31), an end surface action end (32), a spacer (33), an adjustable end of the beam end surface (34), an end surface action end (35), a dial indicator (36), a slotted screw rod (37), a handle nut (38), a T-key (39), a sleeve (40), a protruding block (41), a positioning long pin (42), a table seat (43), a beam end surface fixed end (44), an edge strip outer surface clamping plate (45), a support plate (46), an L-shaped support (47), and a tensioner sleeve (48); The metal joint part (19) comprises a working surface (20) on the web surface side and a working surface (21) on the edge strip surface side; The working surface (20) on the web surface side and the working surface (21) on the flange surface side are offset and manufactured according to theoretical positions on the web surface and flange surface of the composite material box beam; The positioning metal joint part is composed of a platform and a connecting assembly (24); the connecting assembly (24) includes a column (25), a tightener support (26), a tightener (27), a connecting piece (29), and a support (30); The column (25) is fixed on the platform (22) by a mechanical connection method combining screws and pins, and the support (30) is fixed on the column (25) by a mechanical connection method combining screws and pins; The connecting member (29) is fixed on the support (30) by means of a positioning pin. Two pin holes are designed on the connecting member (29) and arranged alternately. The connecting member (29) can be connected and fixed to the metal joint part (19) by means of a metal positioning pin passing through the pin hole. The beam end face adjustable end (34) comprises a metal pin, an end face action end (35), a dial indicator (36), a slotted screw rod (37), a handle screw nut (38), a T-key (39), a sleeve (40), a protruding block (41), a positioning long pin (42), and a dial indicator seat (43); The adjustable end (34) of the beam end face includes a sleeve (40) fixed on the column (25) by a mechanical connection method combining screws and pins; the sleeve (40) has a through hole design inside, one side end of the sleeve (40) adopts a semicircular annular groove design, and the top of the sleeve (40) is designed with a protruding block (41), which is fixed to the top of the sleeve (40) by welding, and the action surface of the protruding block (41) is the action surface of the measuring head of the dial indicator (36); The handle nut (38) is designed with a boss structure on the outside and a threaded hole on the inside. The handle nut (38) cooperates with the semicircular annular groove of the sleeve (40) through its own boss structure. The handle nut (38) and the sleeve (40) are matched with clearance to ensure that the handle nut (38) can rotate around its own axis. One end of the T-key (39) acts on the slotted screw rod (37), and the other end acts on the top of the sleeve (40) and the matching hole that matches the T-key (39); The action surface of the end action end (35) is manufactured by extracting the end surface shape of one side of the composite material sleeve beam, and the end action end (35) is fixed to the slotted screw rod (37) by means of a metal positioning pin connection; The rotation of the handle nut (38) drives the slotted screw (37) to move horizontally, and then drives the end face action end (35) to move horizontally; a through hole is designed at the connection between the sleeve (40) and the slotted screw (37); the diameter of the positioning long pin (42) is consistent with the diameter of the through hole; when the positioning long pin (42) is inserted into the through hole of the sleeve (40) and the slotted screw (37), the theoretical spacing in the axial direction between the action surface of the end face action end (35) and the end surface of one side of the composite material box beam is 5 mm, and the measuring head of the dial indicator (36) is at a position of 10 mm elongation and acts on the action surface of the protruding block (41); The beam end surface fixed end (44) adopts a similar structural form, positioning and movement mode as the beam end surface adjustable end (34). The beam end surface fixed end (44) includes an end surface action end (32), a slotted screw rod (37), a handle nut (38), a T-key (39), a sleeve (40), and a positioning long pin (42). The end surface action end (32) is designed with slotted positions at the positions of the edge strips on both sides of the composite material box beam, and a spacer (33) is placed at the slotted position. The end surface action end (32) is fixed to the slotted screw rod (37) by means of a metal positioning pin connection. The rotation of the handle nut (38) drives the slotted screw (37) to move horizontally, and then drives the end face action end (32) to move horizontally; a through hole is designed at the connection between the sleeve (40) and the slotted screw (37), and the diameter of the positioning long pin (42) is consistent with the diameter of the through hole. When the positioning long pin (42) is inserted into the through hole of the sleeve (40) and the slotted screw (37), the theoretical spacing in the axial direction between the action surface of the end face action end (32) and the end face of the other side of the composite material box beam is 0 mm, that is, the theoretical position of the end face of the other side of the composite material box beam; The action surface of the edge strip profile clamp (45) is manufactured by extracting the edge strip profile of the composite material box beam and offsetting it outward by 2 mm as a reference. The edge strip profile clamp (45) is connected to the support plate (46) by screws and positioning pins; the support plate (46) is positioned and connected to the L-shaped support (47) by screws and positioning pins, and the L-shaped support (47) is fixed on the platform (22) by a mechanical connection method of screws and positioning pins.

2. A method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The composite material box beam forming tool (1) adopts a male mold frame structure design as a whole. The tool material is made of Invar36 steel with an expansion coefficient close to that of the composite material parts. The tool forming surface is extracted according to the theoretical inner surface of the composite material box beam, and the tool forming surface thickness is 10-20mm.

3. A method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1 or 2, characterized in that: The detachable base (4) is designed with a threaded hole for a lifting ring and is provided with a lifting ring (11). After the detachable base (4) slides, it provides space for the detachable carcass (3) to descend, that is, the detachable carcass (3) is detached from the composite material box beam, and then the composite material box beam is demoulded.

4. A method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1 or 2, characterized in that: The metal joint part (19) is extracted from the metal hinge arm (17) in the composite material rudder box section for docking with the aircraft body structure. The metal hinge arm (17) is simplified, the center axis (18) of the intersection of the metal hinge arm is retained and a through hole with a diameter of φ6mm-φ10mm is designed with it as the center. The metal joint part (19) is made of Invar steel.

5. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 3, characterized in that: The metal joint part (19) is extracted from the metal hinge arm (17) in the composite material rudder box section for docking with the aircraft body structure. The metal hinge arm (17) is simplified, the center axis (18) of the intersection of the metal hinge arm is retained and a through hole with a diameter of φ6mm-φ10mm is designed with it as the center. The metal joint part (19) is made of Invar steel.

6. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The length of the working surface of the metal joint part (19) along the axial direction of the composite material box beam is designed to be 150-200 mm; the working surface (20) of the metal joint part (19) located on the web surface side of the composite material box beam is offset by 2 mm toward the inner surface of the composite material box beam according to the theoretical position, that is, there is a theoretical gap of 2 mm between the working surface (20) on the web surface side and the web surface of the composite material box beam; the working surface (21) of the metal joint part (19) located on the edge strip surface side of the composite material box beam is offset by 0.5 mm toward the inner surface of the composite material box beam according to the theoretical position, that is, there is a theoretical gap of 0.5 mm between the working surface (21) on the edge strip surface side and the edge strip surface of the composite material box beam.

7. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The main body of the tensioner support (26) is designed as a cylinder with a through hole design inside. Both ends of the tensioner support (26) have a flange structure design. The flange structure on one side is fixed to the platform (22) by a mechanical connection method combining screws and pins, and the flange structure on the other side is connected and fixed to the tensioner sleeve (48) by a mechanical connection method combining screws and pins; the tensioner sleeve (48) adopts a semicircular annular groove design.

8. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The handle nut (38) is designed with a boss structure on the outside and a threaded hole on the inside. The handle nut (38) cooperates with the semicircular annular groove of the tensioner sleeve (48) through its own boss structure. The handle nut (38) and the tensioner sleeve (48) are clearance-matched to ensure that the handle nut (38) can rotate around its own axis.

9. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The handle nut (38) is designed with a threaded hole inside; the main body of the tensioner (27) is designed with a threaded rod, and the tensioner (27) and the handle nut (38) are threadedly matched. The tensioner (27) is driven to move along its own axial direction by rotating the handle nut (38). The outer diameter of the tensioner (27) is accommodated within the through hole size of the tensioner support (26) to ensure the movement range of the tensioner (27), so that the tensioner (27) can act on the web surface of the composite material box beam to maintain a clamped state, and can also stay away from the web surface of the composite material box beam to maintain a relaxed state to facilitate the loading and disassembly of the composite material box beam.

10. The method for manufacturing a composite material box beam with closed angle ends as claimed in claim 1, characterized in that: The composite cover plate forming tool (13) is made of Invar36 steel with a similar expansion coefficient to the composite cover plate (14); the tool forming surface is manufactured with the outer surface of the pocket surface side of the composite material box beam as the extraction surface; the composite cover plate forming tool (13) adopts a male mold frame structure design; the range of the dial gauge (36) is 0-10mm, and the graduation value is 0.01mm; the measuring rod and the measuring head of the dial gauge (36) are perpendicular to the action surface of the protruding block (41), and the movement direction of the measuring rod and the measuring head of the dial gauge (36) should be parallel to the slot The table base (43) is designed with a through hole, and the table base (43) and the slotted screw (37) are in an interference fit relationship to ensure that the table base (43) is fixed on the slotted screw (37) and moves along the axis direction of the slotted screw (37); the table base (43) is designed with a through hole, and the table base (43) and the shaft sleeve of the dial indicator (36) are in an interference fit relationship to ensure that the dial indicator (36) is fixed on the table base (43), and the measuring rod and the measuring head of the dial indicator (36) are in a relatively free telescopic state.

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