Manufacturing method of foam core material with insert and foam core material with insert

Abstract

The invention belongs to the technical field of composite material detection, and discloses a manufacturing method of a foam core material with an insert and the foam core material with the insert. The manufacturing method of the foam core material with the insert comprises the following steps: preparing raw materials required for forming the foam core material body, and preparing a damaged structural part according to a required damaged shape; the raw materials and the damaged structural part are placed in a mold, the raw materials are foamed, shaped and demolded, and a foam core material body internally provided with the damaged structural part is obtained; the position of the damaged structural part in the foam core material body is detected and marked through detection equipment; and the foam core material body is cut through the cutting mechanism, and the position, in the foam core material body, of the damaged structural part is changed, so that the cut foam core material body obtains a damaged part with the needed shape and position. According to the method, the damage of the required shape and the required position in the foam core material body can be simulated, so that the mechanical property of the damaged foam core material body can be researched.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material detection, and particularly relates to a manufacturing method of foam core material with inserts. BACKGROUND

[0002] The foam core material composite structure has advantages of light structure weight, large bending stiffness, good sound insulation, heat insulation and shock absorption, and has been widely applied to areas such as rudder surfaces, cabin doors and helicopter rotors of civil aircraft. However, in the long-term service process of the foam core material composite structure, the foam core material will be damaged due to its own characteristics, such as internal fracture and fragmentation of the core material. For example, when the foam core material is applied to an aircraft, the generation of core material damage will not only affect the mechanical structure of the part itself, but also cause the part to be scrapped and affect the safe operation of the aircraft. Therefore, research needs to be carried out on the detection method of core material damage and the influence on mechanical properties, but generally speaking, for a formed foam core material structure part, the core material damage occurs in the foam core and cannot be contacted from the outside, and the core material damage generally presents irregular characteristics, so the conventional processing method cannot simulate the damage position inside the core material, and cannot reproduce the irregular damage morphology. SUMMARY

[0003] The purpose of the present application is to provide a manufacturing method of foam core material with inserts, which can simulate the damage of the required shape and position inside the foam core material body, so as to study the mechanical properties of the damaged foam core material body.

[0004] To achieve this purpose, the present application adopts the following technical scheme:

[0005] On the one hand, a manufacturing method of foam core material with inserts is provided, comprising:

[0006] Preparation of raw materials required for forming the foam core material body, preparation of damage structure parts according to the required damage shape;

[0007] Placing the raw materials and the damage structure parts in a mold, and demolding the foam core material body with the damage structure parts inside after the raw materials are foamed and shaped;

[0008] Detecting and marking the position of the damage structure parts inside the foam core material body by a detection device;

[0009] Changing the position of the damage structure parts in the foam core material body by a cutting mechanism, so that the foam core material body after cutting obtains the required shape and position of the damage part.

[0010] As preferred, the raw materials include a foam material, a foaming agent, a catalyst, and a stabilizer.

[0011] As preferred, the foam material, the foaming agent, the catalyst, the stabilizer, and the damage structure are placed in the mold, and stirred by a stirring device to make the foam material, the foaming agent, the catalyst, and the stabilizer be fully stirred and mixed.

[0012] As preferred, the process of making the foam core material with the damage structure inside from the raw materials and the damage structure is performed at room temperature.

[0013] As preferred, the damage structure includes a sheet-shaped structure made of metal material.

[0014] As preferred, the damage structure is made by additive manufacturing technology.

[0015] As preferred, the surface of the damage structure has a plurality of corrugations.

[0016] As preferred, the thickness of the damage structure is 0.1㎜-0.2㎜.

[0017] As preferred, the detection device includes a CT machine for detecting and displaying the coordinate position of the damage structure relative to the foam core material body; and / or

[0018] The cutting mechanism is configured as a cutter or a machine tool.

[0019] In another aspect, a foam core material with an insert is provided, including a foam core material body and a damage structure, the damage structure being arranged in the foam core material body.

[0020] The beneficial effects of the present application are:

[0021] The application provides a manufacturing method of a foam core material with an embedded part. First, raw materials required for forming a foam core material body are prepared, and a damage structure part is prepared according to a required damage shape. The damage structure part is prepared according to a required shape, and the appearance of a damage part inside the foam core material body can be simulated. The raw materials and the damage structure part are placed in a mold, the raw materials are foamed, and after being shaped, the foam core material with the damage structure part inside is obtained. This step enables the damage structure part with a specific shape to be placed inside the foam core material body, so that the shape of a fracture inside the foam core material body can be simulated. The position of the damage structure part inside the foam core material body is detected and marked by a detection device. The foam core material body is cut by a cutting mechanism, and the position of the damage structure part inside the foam core material body is changed, so that the foam core material body obtains a required damage part with a required shape and position. The foam core material body is cut according to the position of the damage structure part inside the foam core material body, so that the position of the damage structure part inside the foam core material body is changed, and the position of the damage part inside the foam core material body is simulated. Thus, the foam core material body with the damage part with the required shape and the required position can be obtained, the mechanical properties of the foam core material body after damage can be researched, and when the foam core material with the embedded part is detected in the subsequent damage detection, the fracture inside the foam core material does not need to be checked by damaging the foam core material, so that the foam core material can be nondestructively detected. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 FIG. 1 is a structural schematic diagram of a foam core material body and a damage structure part provided by an embodiment of the application.

[0023] In the drawings:

[0024] 10, foam core material body; 20, damage structure part. DETAILED DESCRIPTION

[0025] The application will be further described below in conjunction with the drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the application, but not to limit the application. In addition, it should be noted that, for the convenience of description, only the parts related to the application are shown in the drawings, but not all the structures.

[0026] In the description of the application, unless otherwise explicitly specified and limited, the terms "connected", "connected", "fixed" should be understood in a broad sense, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the application can be understood according to the specific circumstances.

[0027] In the present application, unless otherwise explicitly specified and limited, the first feature is "on" or "under" the second feature can include that the first and second features are in direct contact, or can include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, the first feature "on", "above" and "over" the second feature includes that the first feature is directly above and obliquely above the second feature, or only indicates that the first feature is higher in horizontal height than the second feature. The first feature "under", "below" and "underneath" the second feature includes that the first feature is directly below and obliquely below the second feature, or only indicates that the first feature is lower in horizontal height than the second feature.

[0028] In the description of the present embodiment, the terms "upper", "lower", "right", "left", and other orientation or position relationships are based on the orientation or position relationships shown in the drawings, and are only for the convenience of description and simplification of operation, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first" and "second" are only used to distinguish in description and have no special meaning.

[0029] As shown in Figure 1 The present embodiment provides a method for manufacturing a foam core material with inserts, which can simulate the required shape and position of damage inside the foam core material, so as to facilitate the study of the mechanical properties of the damaged foam core material.

[0030] In some embodiments, the method for manufacturing a foam core material with inserts includes the following steps:

[0031] Prepare the raw materials required for forming the foam core body 10, and prepare the damage structure 20 according to the required damage shape; place the raw materials and the damage structure 20 in the mold, and after the raw materials are foamed and set, demold to obtain the foam core body 10 with the damage structure 20 inside; detect and mark the position of the damage structure 20 inside the foam core body 10 through a detection device; cut the foam core body 10 through a cutting mechanism to change the position of the damage structure 20 placed inside the foam core body 10, so that the foam core body 10 obtains the required shape and position of the damage part.

[0032] Specifically, the raw materials include a foaming material, a foaming agent, a catalyst and a stabilizer. The foaming material, the foaming agent, the catalyst and the stabilizer ensure that the foam core body 10 can be made. Taking polyurethane foam as an example, the foaming material is polyol and isocyanate; the foaming agent can be selected from methyl methacrylate, ethyl acrylate, butyl acrylate and styrene, but is not limited thereto; the catalyst can be diorganotin sulfide, tertiary amine and tin compound other than diorganotin sulfide, but is not limited thereto, and the stabilizer can be selected from a PVC stabilizer. The foam core body 10 can also be made of other foaming materials, and the preparation of the foam core body 10 belongs to the prior art, which is not described here.

[0033] Specifically, the foaming material, the foaming agent, the catalyst and the stabilizer and the damage structure 20 are sequentially placed in the mold, and are stirred by the stirring member to make the foaming material, the foaming agent, the catalyst and the stabilizer be fully and uniformly stirred. The foaming material, the foaming agent, the catalyst and the stabilizer are fully stirred by the stirring member to ensure the uniformity and stability of the prepared foam core body 10.

[0034] Preferably, in order to make the reaction effect of the foaming material, the foaming agent, the catalyst and the stabilizer better, the process of making the raw materials and the damage structure 20 into the foam core with the damage structure 20 inside is carried out at room temperature.

[0035] In order to facilitate the detection equipment to mark the position of the damage structure 20 in the foam core body 10 and more intuitively detect the damage structure 20, the damage structure 20 is configured as a sheet structure of metal material. Since the foam core body 10 usually forms a crack inside when natural damage occurs, the damage structure 20 is provided as a sheet to better simulate the morphology of the crack, so that the simulation effect of the damage site is better. In this embodiment, the damage structure 20 is made of stainless steel material, which has the characteristics of corrosion resistance, light weight, convenience and recyclability. First, the damage structure 20 itself is stable, which can better adapt to various foaming materials, foaming agents, catalysts and stabilizers; second, the foam core with the damage structure 20 inside formed is lighter in weight, which is convenient for subsequent mechanical property test and other operations; third, after the mechanical property test and other operations are completed, the damage structure 20 can be recycled, which is beneficial to saving cost.

[0036] Preferably, the damage structure 20 is made by additive manufacturing technology. In this embodiment, the damage structure 20 is prepared by 3D printing technology, which can design and generate a damage structure 20 with any angle and any shape, so that the damage structure 20 can better fit the real foam fracture state.

[0037] Preferably, the surface of the damage structure 20 has several irregularly shaped corrugations. Since the cracks of the foam core body 10 usually present irregular shapes when natural damage occurs, the arrangement of several irregularly shaped corrugations further makes the damage structure 20 more suitable for the real foam fracture state.

[0038] Preferably, the thickness of the damage structure 20 is 0.1-0.2mm. In the embodiment, the thickness of the damage structure 20 is 0.15mm, and the small thickness of the damage structure 20 further makes the damage structure 20 more suitable for the real foam fracture state.

[0039] Specifically, in order to facilitate the detection device to mark the position of the damage structure 20 in the foam core body 10, the detection device includes a CT machine for detecting and displaying the coordinate position of the damage structure 20 relative to the foam core body 10. The CT machine has high-resolution imaging function when detecting, and can quickly detect the position of the damage structure 20 in the foam core body 10, which is beneficial to improve the preparation efficiency.

[0040] Specifically, the cutting mechanism is configured as a cutter or a machine tool. When manually operating the cutting of the foam core body 10, the cutting mechanism is a cutter, and the operator can directly operate the cutter to cut the foam core body 10; when machining is needed to cut the foam core, the cutting mechanism can be a machine tool.

[0041] The embodiment also provides a foam core with an insert, which includes a foam core body 10 and a damage structure 20, and the damage structure 20 is arranged in the foam core body 10.

[0042] Specifically, the method for manufacturing the foam core with an insert includes the following steps:

[0043] Step one, preparing the foam material, foaming agent, catalyst and stabilizer needed for the molding of the foam core body 10.

[0044] Step two, preparing the damage structure 20 according to the required damage shape by 3D printing technology.

[0045] Step three, preparing a mold.

[0046] Step four, placing the foam material, foaming agent, catalyst and stabilizer in the mold, and demolding after the raw materials are foamed and shaped to obtain the foam core with the damage structure 20 arranged inside.

[0047] Step five, detecting and marking the position of the damage structure 20 in the foam core body 10 by a CT machine.

[0048] Step six, according to the position of the damaged structural member 20 in the foam core body 10, the foam core body 10 is cut by a cutter or a machine tool, the position of the damaged structural member 20 in the foam core body 10 is changed, so that the foam core body 10 obtains the required shape, position of the damaged part.

[0049] Obviously, the above-mentioned embodiments of the present application are only examples for clearly illustrating the present application, and are not intended to limit the embodiments of the present application. For those skilled in the art, various obvious changes, re-adjustments and substitutions can be made without departing from the scope of the present application. Here, it is not necessary and impossible to exhaust all the embodiments. Any modification, equivalent substitution and improvement within the spirit and principle of the present application shall be included in the protection scope of the claims of the present application.

Claims

1. A method for manufacturing a foam core material with an insert, characterized in that: include: preparing raw materials required for forming the foam core material body (10), and preparing a damaged structural part (20) according to the required damage shape; The raw material and the damaged structural part (20) are placed in a mold, and after the raw material is foamed and shaped, the mold is removed to obtain the foam core material body (10) with the damaged structural part (20) provided therein; Detecting and marking the position of the damaged structural component (20) in the foam core material body (10) using a detection device; The foam core material body (10) is cut by a cutting mechanism, and the position of the damaged structural component (20) in the foam core material body (10) is changed, so that the foam core material body (10) after cutting obtains a damaged part with a desired shape and position.

2. The method for manufacturing a foam core material with an insert according to claim 1, wherein: The raw materials include foam material, foaming agent, catalyst and stabilizer.

3. The method for manufacturing a foam core material with an insert according to claim 2, characterized in that: The foam material, the foaming agent, the catalyst, the stabilizer and the damaged structural member (20) are placed in the mold and stirred by a stirring member so that the foam material, the foaming agent, the catalyst and the stabilizer are fully and uniformly stirred.

4. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The process of manufacturing the foam core material with the damaged structural part (20) inside from the raw materials and the damaged structural part (20) is carried out at room temperature.

5. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The damaged structural member (20) comprises a sheet-like structure made of metal material.

6. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The damaged structural component (20) is manufactured using additive manufacturing technology.

7. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The surface of the damaged structural member (20) has a plurality of corrugations.

8. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The thickness of the damaged structural member (20) is 0.1 mm to 0.2 mm.

9. The method for manufacturing a foam core material with an insert according to any one of claims 1 to 3, characterized in that: The detection equipment includes a CT machine, and the CT machine is used to detect and display the coordinate position of the damaged structural component (20) relative to the foam core material body (10); and / or The cutting mechanism is configured as a tool or a machine tool.

10. A foam core material with an insert, comprising a foam core material body (10) and a damaged structural member (20), wherein the damaged structural member (20) is arranged in the foam core material body (10).

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