Process method and system for reinforcing fiber distribution optimization in composite material printing

Abstract

The invention relates to the technical field of composite material printing, and discloses a process method and system for optimizing distribution of reinforced fibers in composite material printing, and the process method comprises the steps of mixing and preparation of reinforced fibers and a matrix material, path planning and fiber distribution design, real-time fiber conveying and mixed output, and laser heating and immediate curing. Online detection, feedback optimization, printing post-processing and quality verification are carried out. According to the invention, the uniform distribution of the fibers and the matrix material improves the interlayer bonding strength, and the bonding strength is improved by 30%-50%; by means of optimized fiber direction arrangement, the part has excellent mechanical performance under multi-directional loads, the breaking strength is improved by 40%, and the fatigue life is prolonged by two times; fiber consumption is reduced in a low-stress area, mechanical requirements are met, material cost is saved, and the cost is reduced by about 20%; and a real-time monitoring and closed-loop feedback mechanism ensures the distribution uniformity of each layer of fibers, so that the quality stability of a printing part is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of composite material printing, and particularly to a process method and system for optimizing the distribution of reinforcing fibers in composite material printing. Background Art

[0002] In composite material printing, the uniform distribution of reinforcing fibers is a key factor affecting the mechanical properties (such as strength, toughness, and stiffness) of components. However, in traditional 3D printing methods, the distribution of reinforcing fibers is often limited by the following problems:

[0003] 1. Uneven fiber distribution: Fibers are prone to accumulate or segregate in the matrix material, resulting in local stress concentration.

[0004] 2. Uncontrollable fiber direction: The directionality of reinforcing fibers is difficult to precisely control, affecting the anisotropic properties of composite materials.

[0005] 3. Limited equipment accuracy: Traditional equipment is difficult to adjust the fiber length, arrangement direction, and distribution density in real time.

[0006] Therefore, a process method based on optimizing the distribution of reinforcing fibers is needed to achieve precise distribution and arrangement of fibers through coordinated software and hardware control. Summary of the Invention

[0007] To solve the above problems, the present invention discloses a process method and system for optimizing the distribution of reinforcing fibers in composite material printing; precise distribution and arrangement of fibers are achieved through coordinated software and hardware control; the interfacial bonding strength is significantly improved

[0008] A process method for optimizing the distribution of reinforcing fibers in composite material printing includes the following steps:

[0009] Step 1, mixing and preparation of reinforcing fibers and matrix material: Select reinforcing fibers (carbon fiber or glass fiber) and matrix material (such as PLA, nylon) according to printing requirements, cut and mix the fibers;

[0010] Step 2, path planning and fiber distribution design: Use mechanical simulation software to analyze the load of the component, determine the high-stress areas and their fiber distribution density; in the high-stress areas, lay multiple layers and alternate directions, and reduce the fiber density in the low-stress areas to save materials;

[0011] Step 3, real-time optimization during the printing process:

[0012] Fiber feeding: Fibers are fed to the nozzle through a roller feeding system and dynamically mixed with the matrix material; sensors monitor the fiber length and flow rate in real time to ensure uniform fiber distribution;

[0013] Printing path execution: The nozzle moves according to the path planning, and instantaneously cures the printing material in combination with the laser heating module; the laser curing power and the spraying rate are adjusted in real time through closed-loop control.

[0014] Step 4, On-line detection and feedback control: Use a laser scanner and an optical camera to detect the fiber distribution of the printed layer in real time, and analyze the fiber direction deviation and density non-uniformity problems; if a deviation is detected, correct it by adjusting the nozzle speed or the fiber feeding rate.

[0015] Step 5, Post-printing processing: After printing is completed, use ultrasonic scanning to detect the interlayer bonding strength and fiber distribution; use finite element analysis to verify the mechanical properties of the printed component under actual loads.

[0016] Furthermore, in Step 1, the reinforcing fibers (such as carbon fibers or glass fibers) are transported through a high-precision roller feeding device and cut to a uniform length of 5 mm - 15 mm. These fibers are fully mixed with the matrix material (such as PLA or nylon) in a dynamic shear mixer in a set ratio. The shear mixer can adjust the mixing strength in real time to ensure that the fibers do not agglomerate and are evenly distributed.

[0017] Furthermore, in Step 2, a three-dimensional model of the printed component is built based on the CAD model, and a mechanical simulation software is used to analyze the load distribution and stress concentration areas of the component. Through the path planning and distribution optimization module, a reinforcement path for high-stress areas and a fiber-sparse path for low-stress areas are generated. The path planning adopts a zoning strategy, and multi-directional alternating laying (such as 0°, ±45°, 90°) is used in high-stress areas to enhance the overall strength and toughness of the component. The optimization module also considers the alignment of the fiber direction to ensure that the anisotropic properties of the composite material meet the design requirements.

[0018] Furthermore, in Step 3, during the printing process, the reinforcing fibers are transported to the nozzle at a set speed through a roller feeding system. The shear mixer inside the nozzle dynamically adjusts the ratio of the fibers to the matrix material, and combines sensors to monitor the fiber flow rate and distribution density in real time to ensure the uniformity of the output material. The dual-channel design of the nozzle supports the simultaneous output of different materials, and adjusts the fiber feeding speed according to the requirements of the printing path through a closed-loop control system to achieve precise laying in multiple layers and multiple directions.

[0019] Furthermore, in Step 4, during the printing process, the laser heating module integrated in the nozzle dynamically adjusts the power distribution through a thermodynamic model to provide uniform heating for each layer of printing material. The laser curing process can not only quickly fix the output material, but also fully fuse the fibers with the matrix material through local heat treatment. The dynamic power adjustment function of the laser can avoid material decomposition caused by overheating and ensure the bonding strength between each layer of materials.

[0020] Furthermore, after each layer of printing is completed, a laser scanner and an optical camera are used to perform real-time detection of the fiber distribution. Based on the data collected by the sensors, the directionality and density uniformity of the fiber distribution are analyzed. If problems such as direction deviation or uneven distribution are detected, the closed-loop control system will adjust the movement speed of the nozzle, the fiber feeding rate, and the laser power in real time to ensure that the printing quality of the next layer meets the design requirements. This process ensures the consistency of the fiber distribution and the stability of the material properties.

[0021] Furthermore, after printing is completed in step five, ultrasonic scanning technology is used to perform non-destructive detection of the interlayer bonding strength and fiber distribution of the printed component. Infrared thermal imaging is used to verify the uniformity of the heat treatment between layers and the internal defect conditions of the material. In addition, combined with finite element analysis, the actual load distribution and stress conditions of the printed component are verified. The results are fed back to the optimization module to provide data support and a basis for process improvement for future printing tasks. This working principle ensures the high quality and mechanical properties of the printed component.

[0022] Another object of the present invention is to provide a system for optimizing the distribution of reinforcing fibers in composite material printing, including:

[0023] A multi-functional nozzle system, equipped with a dual-channel design and a dynamic shear mixer, and embedded with a laser heating module;

[0024] Dual-channel design: One channel is for the matrix material (resin or thermoplastic), and the other channel is for the reinforcing fibers (such as carbon fiber, glass fiber);

[0025] Dynamic shear mixer: Used to uniformly mix the fibers and the matrix before spraying;

[0026] Laser heating module: Used to cure the printing material in real time and control the fiber orientation;

[0027] Fiber feeding device, using a high-precision roller feeding device to convey the fibers at a set speed and length; equipped with an automatic cutting module to support the mixed distribution of fibers of multiple lengths;

[0028] Printing bed and positioning device, including a heating-type printing bed with a temperature range of 30°C - 150°C, used to improve the adhesion of the printing layer; a three-axis high-precision displacement platform with an accuracy of ±10μm, used to control the position of the nozzle.

[0029] Sensor network, equipped with an optical camera, ultrasonic sensors, and a laser scanner, used to monitor the fiber distribution and arrangement in real time.

[0030] Furthermore, the system for optimizing the distribution of reinforcing fibers in composite material printing includes:

[0031] Path Planning and Distribution Optimization Module: Automatically generate printing paths based on CAD models, and optimize fiber direction and density distribution according to the load analysis results; support multi-directional alternating laying (such as 0°, ±45°, 90°) to achieve multi-directional superposition of reinforcing fibers.

[0032] Fiber Distribution Feedback Control Module: Combine the data collected by sensors and dynamically adjust the nozzle output rate, fiber feeding rate, and mixing ratio through closed-loop control algorithms.

[0033] Mechanical Property Simulation Module: Integrate finite element analysis tools to perform mechanical simulations on fiber distribution models and verify the effectiveness of fiber distribution schemes.

[0034] Another object of the present invention is to provide an information data processing terminal, and the information data processing terminal includes the system for optimizing the distribution of reinforcing fibers in composite material printing described above.

[0035] Advantages of the present invention:

[0036] 1. Significantly improve the interfacial bonding strength;

[0037] The uniform distribution of fibers and matrix materials improves the interlayer bonding strength, and the bonding strength is increased by 30%-50%.

[0038] 2. Enhance mechanical properties;

[0039] The optimized fiber direction arrangement enables the component to have excellent mechanical properties under multi-directional loads, with the fracture strength increased by 40% and the fatigue life extended by 2 times.

[0040] 3. Achieve resource conservation;

[0041] Reduce the fiber usage in low-stress areas, save material costs while meeting mechanical requirements, and reduce costs by about 20%.

[0042] 4. Improve printing quality and consistency;

[0043] Real-time monitoring and closed-loop feedback mechanisms ensure the uniformity of fiber distribution in each layer, improving the quality stability of printed components.

[0044] 5. Wide applicability;

[0045] This process method is applicable to fields with high requirements for composite material performance such as aerospace, automotive manufacturing, and medical devices. Description of the Drawings

[0046] Figure 1 is a process method flow chart for optimizing the distribution of reinforcing fibers in composite material printing provided by an embodiment of the present invention;

[0047] Figure 2It is the system structure diagram for optimizing the distribution of reinforcing fibers in composite material printing provided by an embodiment of the present invention. Detailed implementation manners

[0048] The present invention will be further clarified below in conjunction with the accompanying drawings and specific implementation manners. It should be understood that the following specific implementation manners are only used to illustrate the present invention and not to limit the scope of the present invention. It should be noted that the terms "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to the directions in the accompanying drawings, and the terms "inner" and "outer" respectively refer to the directions towards or away from the geometric center of a specific component.

[0049] As Figure 1 shown, an embodiment of the present invention provides a process method for optimizing the distribution of reinforcing fibers in composite material printing, including the following steps:

[0050] Step 1, mixing and preparation of reinforcing fibers and matrix materials: Select reinforcing fibers (carbon fibers or glass fibers) and matrix materials (such as PLA, nylon) according to printing requirements; set the fiber cutting length to 5 mm - 15 mm to ensure uniform distribution after mixing;

[0051] Step 2, path planning and fiber distribution design: Use mechanical simulation software to perform load analysis on the component to determine the high-stress areas and their fiber distribution densities; adopt multi-layer and multi-directional alternating laying in the high-stress areas, and reduce the fiber density in the low-stress areas to save materials;

[0052] Step 3, real-time optimization during printing:

[0053] Fiber feeding: The fibers are transported to the nozzle through a roller feeding system and dynamically mixed with the matrix material; sensors monitor the fiber length and flow rate in real time to ensure uniform fiber distribution;

[0054] Printing path execution: The nozzle moves according to the path planning, and the printing material is instantaneously cured in combination with a laser heating module; the laser curing power and spraying rate are adjusted in real time through closed-loop control.

[0055] Step 4, online detection and feedback control: Use a laser scanner and an optical camera to detect the fiber distribution of the printed layer in real time, and analyze problems such as fiber direction deviation and density non-uniformity; if a deviation is detected, correct it by adjusting the nozzle speed or fiber feeding rate;

[0056] Step 5, post-printing treatment: After printing is completed, use ultrasonic scanning to detect the interlayer bonding strength and fiber distribution; use finite element analysis to verify the mechanical properties of the printed component under actual loads.

[0057] 1. Mixing and preparation of reinforcing fibers and matrix materials

[0058] The precise preparation of reinforcing fibers and matrix materials is a key step in achieving uniform fiber distribution. Reinforcing fibers (such as carbon fibers or glass fibers) are transported through a high-precision roller feeding device and cut to a uniform length of 5 mm - 15 mm. These fibers are fully mixed with the matrix material (such as PLA or nylon) in a dynamic shear mixer in a set ratio. The shear mixer can adjust the mixing intensity in real time to ensure that the fibers do not agglomerate and are evenly distributed. The mixed material is output from the nozzle, laying a foundation for uniform distribution in subsequent printing.

[0059] 2. Path Planning and Fiber Distribution Design

[0060] Based on the CAD model, a 3D model of the printed part is built, and a mechanical simulation software is used to analyze the load distribution and stress concentration areas of the part. Through the path planning and distribution optimization module, reinforcement paths for high-stress areas and fiber-sparse paths for low-stress areas are generated. The path planning adopts a zoning strategy, and in high-stress areas, multi-directional alternating laying (such as 0°, ±45°, 90°) is used to enhance the overall strength and toughness of the part. The optimization module also considers the alignment of fiber directions to ensure that the anisotropic properties of the composite material meet the design requirements.

[0061] 3. Real-time Fiber Conveying and Mixed Output

[0062] During the printing process, the reinforcing fibers are conveyed to the nozzle at a set speed through a roller feeding system. The shear mixer in the nozzle dynamically adjusts the ratio of fibers to the matrix material, and combines with sensors to monitor the fiber flow rate and distribution density in real time to ensure the uniformity of the output material. The dual-channel design of the nozzle supports the simultaneous output of different materials, and adjusts the fiber feeding speed according to the requirements of the printing path through a closed-loop control system to achieve precise laying in multiple layers and multiple directions.

[0063] 4. Laser Heating and Instantaneous Curing

[0064] During the printing process, the laser heating module integrated in the nozzle dynamically adjusts the power distribution through a thermodynamic model to provide uniform heating for each layer of printed material. The laser curing process can not only quickly fix the output material, but also make the fibers and the matrix material fully fused through local heat treatment. The dynamic power adjustment function of the laser can avoid material decomposition caused by overheating, and at the same time ensure the bonding strength between each layer of materials.

[0065] 5. Online Detection and Feedback Optimization

[0066] After each layer is printed, a laser scanner and an optical camera are used to detect the fiber distribution in real time. Based on the data collected by the sensors, the directionality and density uniformity of the fiber distribution are analyzed. If any directional deviation or uneven distribution issues are detected, the closed-loop control system will adjust the movement speed of the nozzle, the fiber feeding rate, and the laser power in real time to ensure that the printing quality of the next layer meets the design requirements. This process ensures the consistency of the fiber distribution and the stability of the material properties.

[0067] 6. Post-printing Processing and Quality Verification

[0068] After printing is completed, ultrasonic scanning technology is used to perform non-destructive detection on the interlayer bonding strength and fiber distribution of the printed components. Infrared thermal imaging is used to verify the heat treatment uniformity between layers and the internal defect conditions of the material. In addition, combined with finite element analysis, the actual load distribution and stress conditions of the printed components are verified. The results are fed back to the optimization module to provide data support and process improvement basis for future printing tasks. This working principle ensures the high quality and mechanical properties of the printed components.

[0069] As Figure 2 shown, an embodiment of the present invention provides a system for optimizing the distribution of reinforcing fibers in composite material printing, including:

[0070] A multi-functional nozzle system, equipped with a dual-channel design and a dynamic shear mixer, and embedded with a laser heating module;

[0071] Dual-channel design: One channel is for the matrix material (resin or thermoplastic), and the other channel is for the reinforcing fibers (such as carbon fiber, glass fiber);

[0072] Dynamic shear mixer: Used to uniformly mix the fibers and the matrix before spraying;

[0073] Laser heating module: Used to cure the printing material in real time and control the fiber orientation;

[0074] A fiber feeding device, using a high-precision roller feeding device to convey fibers at a set speed and length; equipped with an automatic cutting module to support the mixed distribution of fibers of multiple lengths;

[0075] A printing bed and a positioning device, including a heating-type printing bed with a temperature range of 30°C - 150°C, used to improve the adhesion of the printed layer; a three-axis high-precision displacement platform with an accuracy of ±10μm, used to control the nozzle position.

[0076] A sensor network, equipped with an optical camera, an ultrasonic sensor, and a laser scanner, used to monitor the fiber distribution and arrangement in real time.

[0077] Furthermore, the system for optimizing the distribution of reinforcing fibers in composite material printing includes:

[0078] Path Planning and Distribution Optimization Module: Automatically generate printing paths based on CAD models, and optimize fiber orientation and density distribution according to the results of load analysis; support multi-directional alternating laying (such as 0°, ±45°, 90°) to achieve multi-directional superposition of reinforcing fibers.

[0079] Fiber Distribution Feedback Control Module: Combine the data collected by sensors and dynamically adjust the nozzle output rate, fiber feeding rate, and mixing ratio through closed-loop control algorithms.

[0080] Mechanical Property Simulation Module: Integrate finite element analysis tools to perform mechanical simulations on fiber distribution models and verify the effectiveness of fiber distribution schemes.

[0081] It should be noted that the embodiments of the present invention can be implemented through hardware, software, or a combination of software and hardware. The hardware part can be implemented using dedicated logic; the software part can be stored in a memory and executed by an appropriate instruction execution system, such as a microprocessor or dedicated design hardware. Those of ordinary skill in the art can understand that the above devices and methods can be implemented using computer-executable instructions and / or included in processor control code, for example, such code is provided on a carrier medium such as a disk, CD, or DVD-ROM, a programmable memory such as a read-only memory (firmware), or a data carrier such as an optical or electronic signal carrier. The devices and modules of the present invention can be implemented by hardware circuits of programmable hardware devices such as very large-scale integrated circuits or gate arrays, semiconductors such as logic chips and transistors, or programmable logic devices such as field programmable gate arrays, and can also be implemented by software executed by various types of processors, or can be implemented by a combination of the above hardware circuits and software, such as firmware.

[0082] The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A process for optimizing the distribution of reinforcing fibers in composite material printing, characterized in that: The following steps are involved: Step 1: Mixing and preparing reinforcing fibers and matrix materials: Select reinforcing fibers and matrix materials according to printing requirements, cut and mix the fibers; The reinforcing fiber is carbon fiber or glass fiber, and the matrix material is PLA or nylon; Step 2: Path planning and fiber distribution design: Use mechanical simulation software to analyze the load of the component and determine the high stress area and its fiber distribution density; use multi-layer and multi-directional alternating laying in the high stress area and reduce the fiber density in the low stress area; Step 3: Real-time optimization during printing: Fiber delivery: Fibers are delivered to the nozzle through a roller feeding system and dynamically mixed with the matrix material; sensors monitor fiber length and flow in real time to ensure uniform fiber distribution; Printing path execution: The nozzle moves according to the path planning, and combines with the laser heating module to instantly solidify the printed material; the laser curing power and spraying rate are adjusted in real time through closed-loop control; Step 4: Online detection and feedback control: Use laser scanners and optical cameras to detect the fiber distribution of the printed layer in real time, and analyze the fiber direction deviation and density unevenness. If deviation is detected, it is corrected by adjusting the nozzle speed or fiber feed rate. Step 5: Post-printing processing: After printing is completed, ultrasonic scanning is used to detect the interlayer bonding strength and fiber distribution, and finite element analysis is used to verify the mechanical properties of the printed parts under actual loads.

2. A process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 1, characterized in that: In step 1, the reinforcing fibers are fed through a high-precision roller feed device and cut to a uniform length of 5 mm-15 mm; these fibers are fully mixed with the matrix material in a set ratio in a dynamic shear mixer; the shear mixer adjusts the mixing intensity in real time to ensure that the fibers do not agglomerate and are evenly distributed.

3. The process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 1, characterized in that: In step 2, three-dimensional modeling of the printed component is performed based on the CAD model, and mechanical simulation software is used to analyze the load distribution and stress concentration area of ​​the component; Through the path planning and distribution optimization module, a reinforcement path including high stress areas and a fiber sparse path in low stress areas is generated; The path planning adopts a zoning strategy, and high-stress areas are laid alternately in multiple directions, including 0°, ±45°, and 90°, to enhance the overall strength and toughness of the components; the optimization module also considers the alignment of the fiber direction to ensure that the anisotropic properties of the composite material meet the design requirements.

4. The process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 1, characterized in that: Step 3: During the printing process, the reinforced fibers are delivered to the nozzle at a set speed through the roller feeding system; the shear mixer in the nozzle dynamically adjusts the ratio of fiber to matrix material, and combines with sensors to monitor fiber flow and distribution density in real time to ensure the uniformity of the output material; the dual-channel design of the nozzle supports the simultaneous output of different materials, and adjusts the fiber feeding speed according to the requirements of the printing path through a closed-loop control system to achieve multi-level and multi-directional precise laying.

5. The process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 1, characterized in that: Step 4: During the printing process, the laser heating module integrated in the nozzle dynamically adjusts the power distribution through the thermodynamic model to provide uniform heating for each layer of printed material. The laser curing process can not only quickly fix the output material, but also fully integrate the fiber and the matrix material through local heat treatment. The dynamic power adjustment function of the laser avoids material decomposition caused by overheating, while ensuring the bonding strength between each layer of material.

6. The process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 5, characterized in that: Laser scanners and optical cameras detect fiber distribution in real time after each layer is printed. The directionality and density uniformity of fiber distribution are analyzed through data collected by sensors. If directional deviation or uneven distribution is detected, the closed-loop control system will adjust the movement speed of the nozzle, fiber feed rate and laser power in real time to ensure that the quality of the next layer of printing meets the design requirements.

7. The process for optimizing the distribution of reinforcing fibers in composite material printing according to claim 1, characterized in that: After printing is completed in step 5, ultrasonic scanning technology is used to perform non-destructive testing on the interlayer bonding strength and fiber distribution of the printed parts; infrared thermal imaging is used to verify the uniformity of heat treatment between layers and the internal defects of the material; In addition, the actual load distribution and stress conditions of the printed parts are verified in combination with finite element analysis, and the results are fed back to the optimization module.

8. A system for optimizing the distribution of reinforcing fibers in composite material printing according to any one of claims 1 to 7, characterized in that: include: Multifunctional nozzle system with dual-channel design and dynamic shear mixer, and built-in laser heating module; Dual-channel design: one channel for matrix material and another for reinforcing fibers; Dynamic shear mixer: used to evenly mix the fiber and matrix before spraying; Laser heating module: used to solidify printed materials in real time and control fiber orientation; Fiber feeding device, using high-precision roller feeding device to deliver fiber at set speed and length; Equipped with automatic cutting module, supporting mixed distribution of multi-length fibers; The print bed and positioning device include a heated print bed with a temperature range of 30°C-150°C for improving the adhesion of the printed layer; a three-axis high-precision displacement platform with an accuracy of ±10 μm for controlling the position of the nozzle; and a sensor network equipped with optical cameras, ultrasonic sensors and laser scanners for real-time monitoring of fiber distribution and arrangement.

9. The system for optimizing the distribution of reinforcing fibers in composite material printing according to claim 8, characterized in that: include: Path planning and distribution optimization module: automatically generates printing paths based on CAD models, and optimizes fiber direction and density distribution according to load analysis results; supports multi-directional alternating laying, including 0°, ±45°, and 90°, to achieve multi-directional superposition of reinforced fibers; fiber distribution feedback control module: combines data collected by sensors to dynamically adjust the nozzle output rate, fiber feed rate, and mixing ratio through a closed-loop control algorithm; mechanical properties simulation module: integrates finite element analysis tools to perform mechanical simulation on the fiber distribution model to verify the effectiveness of the fiber distribution scheme.

10. An information data processing terminal, characterized in that: The information data processing terminal includes the system for optimizing the distribution of reinforcing fibers in composite material printing as described in claim 8.

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