A low-loss preparation method of ceramic panel based on arrangement algorithm optimization

Abstract

This invention relates to the field of protective equipment manufacturing, specifically a low-loss preparation method for ceramic panels based on layout algorithm optimization. The method first acquires the two-dimensional contour data of the ceramic panel to be prepared and the geometric parameters of individual hexagonal ceramic sheets, constructing a corresponding digital model. Then, an layout optimization algorithm is introduced, with the objective function being the minimum number of ceramic sheets used and the minimum cumulative cutting cross-sectional length, to calculate and output the optimal laying scheme. Based on the optimal parameters, a solid limiting mold with a grid positioning structure is fabricated. Using the mold, the ceramic sheets are precisely arrayed and laid between the fiber-reinforced material and the adhesive film layer. After removing the mold, a preform is obtained. This preform is then subjected to high-temperature, high-pressure hot-pressing composite curing and precisely cut along a predetermined contour to obtain the finished product. This process significantly reduces the ceramic waste rate and the difficulty of subsequent cutting, eliminates the cumulative error of manual layout, and effectively improves the structural consistency and large-scale production efficiency of armor and ballistic protection panels.

Description

Technical Field

[0001] This invention relates to the field of protective equipment manufacturing technology, specifically to a low-loss preparation method for ceramic panels based on layout algorithm optimization. Background Technology

[0002] Ceramic panels, as a protective material with high hardness, low density, and excellent ballistic resistance, play an irreplaceable role in individual soldier armor and special vehicle defense. Their core protective mechanism utilizes the kinetic energy dissipation caused by the fragmentation of the ceramic material under high-energy impact, thereby effectively protecting subsequent targets.

[0003] Traditional ceramic panel manufacturing often employs a process of integral molding followed by mechanical cutting, or relies on simple manual arrangement based on experience. This manufacturing method typically lacks precise layout planning, resulting in extremely arbitrary placement of ceramic sheets at the edges. Furthermore, the cutting process after composite curing often requires blindly cutting a large amount of high-hardness ceramic.

[0004] Due to the lack of digital layout methods, existing technologies suffer from severe material loss, especially for expensive ceramic materials such as boron carbide, where the scrap rate often reaches 20% to 30%. Furthermore, high-hardness ceramics are highly susceptible to edge micro-cracks or chipping defects during cutting, and the uneven gaps caused by low precision in manual layout directly weaken the overall protective consistency of the product, increasing production costs and reducing manufacturing efficiency. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a low-loss preparation method for ceramic panels based on layout algorithm optimization, which solves the problems of low material utilization, difficult cutting and processing, and poor layout accuracy mentioned in the background technology.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a low-loss preparation method for ceramic panels based on arrangement algorithm optimization, comprising the following steps:

[0007] Step A: Obtain two-dimensional contour data characterizing the target shape of the ceramic panel to be prepared, and construct a digital model of the target cutting area accordingly; simultaneously extract the geometric parameters of the hexagonal ceramic sheet to establish a digital model of the individual ceramic sheet;

[0008] Step B: Import the target cutting area and the digital model of the individual ceramic sheet into the same two-dimensional plane space, and use the position coordinates and rotation angle of the ceramic sheet array as the core variables to perform a simulated laying operation;

[0009] Step C: Introduce a layout optimization algorithm for iterative calculation. The objective functions are to minimize the number of ceramic tiles required to cover the target cutting area and to minimize the cumulative length of the ceramic tile cross-section cut by the boundary line of the target cutting area. The output is the optimal laying scheme that covers the position coordinates and arrangement angle of the ceramic tile array.

[0010] Step D: Construct a digital model of the limiting mold based on the optimal laying scheme, and use rapid prototyping technology to process a physical limiting mold with a grid positioning structure, so that the grid positioning structure matches the optimal laying scheme;

[0011] Step E: Lay the lower layer adhesive film and the lower layer fiber reinforcement material sequentially on the operating platform, and position the solid limiting mold on it; fill the grid positioning structure of the solid limiting mold one by one with hexagonal ceramic sheets, and remove the mold after filling is completed; then lay the upper layer adhesive film and the upper layer fiber reinforcement material sequentially on the ceramic sheet layer to obtain the ceramic panel preform.

[0012] Step F: The formed ceramic panel preform is transferred to a high-temperature and high-pressure equipment for hot-pressing composite curing treatment to prepare a ceramic panel blank with the same layout as the optimal laying scheme.

[0013] Step G: Retrieve the two-dimensional contour data of the ceramic panel to be prepared as a path guide, and precisely cut the ceramic panel blank along the specified trajectory to obtain the finished ceramic panel.

[0014] Preferably, the two-dimensional contour data of the ceramic panel to be prepared is a closed outer boundary coordinate dataset that outlines the target shape of the ceramic panel; the geometric parameters of the hexagonal ceramic sheet are the side lengths of the hexagon.

[0015] Preferably, the layout optimization algorithm used to perform the optimization operation includes genetic algorithm, particle swarm optimization algorithm, simulated annealing algorithm or step size search algorithm;

[0016] The specific procedure for the simulated laying is as follows: individual ceramic pieces are preset to be arranged in an array, with a preset gap between the individual ceramic pieces that is equal to the size of the positioning structure of the physical limiting mold grid, and the total area of ​​the generated ceramic piece array is larger than the target cutting area; the position coordinates (x, y) of the ceramic piece array relative to the target cutting area and the rotation angle θ are defined as optimization variables, and iterative optimization calculations are performed in the two-dimensional plane based on the arrangement optimization algorithm to approximate the extreme point of the objective function.

[0017] Preferably, the objective function is defined as follows: the total number of ceramic pieces required to fully cover the target cutting area reaches a minimum value, and the total length of the ceramic piece cross-section cut off by the boundary line of the target cutting area reaches a minimum value.

[0018] Preferably, the process of constructing the digital model of the limiting mold in step D is as follows:

[0019] Create a mold base model that can completely cover the target cutting area;

[0020] The ceramic tile array position coordinates and rotation angle data established in the optimal laying scheme are called to generate the corresponding ceramic tile array model in digital space;

[0021] Using Boolean subtraction logic, the volume occupied by the ceramic sheet array model is removed from the mold base model to obtain a two-dimensional model of the limiting mold with a grid positioning structure.

[0022] The two-dimensional model is stretched along a direction perpendicular to the plane, and the stretching thickness is set to match the thickness of the hexagonal ceramic sheet to generate a three-dimensional digital model of the limiting mold.

[0023] Preferably, the rapid prototyping technology is selected from fused deposition modeling, stereolithography, or laser cutting; the material of the solid limiting mold is selected from polylactic acid, acrylonitrile-butadiene-styrene copolymer, photosensitive resin, nylon sheet, or polymethyl methacrylate sheet.

[0024] Preferably, the adhesive film is selected from thermoplastic polyurethane film, ethylene-vinyl acetate copolymer film, polyvinyl butyral film, or epoxy resin film; the lower fiber reinforcement material and the upper fiber reinforcement material are selected from one or more composite compositions of ultra-high molecular weight polyethylene fiber cloth, aramid fiber cloth, glass fiber cloth, or carbon fiber cloth.

[0025] Preferably, after removing the physical limiting mold and before laying the upper adhesive film, the process further includes:

[0026] The arrangement position of each individual ceramic sheet in the ceramic sheet array is checked, and individual ceramic sheets whose positions deviate from the preset coordinates are reset and adjusted.

[0027] Gap filling material is used to fill and reinforce the gaps between the arranged ceramic tiles.

[0028] Preferably, the high-temperature and high-pressure equipment is an autoclave, and its process control parameters are set as follows: the curing temperature threshold is 120°C to 180°C, the curing pressure is 0.3MPa to 1.0MPa, and the heat preservation and pressure holding time is 60 to 180 minutes.

[0029] Preferably, the cutting action in step G is performed using a ceramic cutting machine, and the cutting tool performs a through-cutting separation of the solidified ceramic panel blank along the contour line of the ceramic panel to be prepared.

[0030] This invention provides a low-loss fabrication method for ceramic panels based on an optimized arrangement algorithm. It offers the following advantages:

[0031] 1. This invention significantly improves the utilization rate of ceramic materials by introducing an arrangement optimization algorithm and using the number of ceramic pieces and cutting length as dual optimization objectives during the design phase. The algorithm seeks the optimal solution with minimal edge truncation of ceramic pieces by adjusting the array offset and rotation angle in a global coordinate system, thereby reducing the generation of waste ceramic fragments at the source and greatly lowering the production cost of expensive ceramic materials.

[0032] 2. This invention utilizes a physical positioning mold prepared with the aid of digital modeling and rapid prototyping technology to achieve precise mapping from virtual design to physical arrangement of ceramic sheets. The grid positioning structure forcibly constrains the spatial position of each hexagonal ceramic sheet, eliminating the cumulative errors and randomness caused by manual arrangement, ensuring the consistency of the gaps between ceramic sheets, thereby guaranteeing the structural stability and balanced protective performance of the protective panel at the physical level.

[0033] 3. This invention relies on the high consistency between the digital cutting path generated by the algorithm and the physical layout scheme, effectively reducing the processing intensity of subsequent cutting processes. Since the optimal laying scheme has minimized the length of the cut ceramic, the time the cutting machine contacts the high-hardness ceramic surface during processing is shortened. This not only protects the cutting tool and reduces wear, but also effectively avoids edge cracks and chipping caused by excessive cutting of the ceramic, thus improving the structural integrity of the finished product.

[0034] 4. The manufacturing process of this invention achieves end-to-end digital integration from two-dimensional contour scanning, algorithm optimization, rapid mold manufacturing to automatic alignment and cutting. This production mode eliminates reliance on highly skilled workers, guiding physical manufacturing through optimal mathematical calculations, significantly shortening the cycle from design to finished product, and ensuring high controllability of product quality and batch stability while improving layout efficiency. Attached Figure Description

[0035] Figure 1 This is a schematic flowchart of the low-loss ceramic panel preparation method of the present invention;

[0036] Figure 2 This is a schematic diagram illustrating the iterative optimization of the layout using a genetic algorithm, as described in this invention. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example:

[0039] like Figure 1-2 As shown, this embodiment of the invention provides a low-loss ceramic panel fabrication method based on layout algorithm optimization, comprising the following steps:

[0040] Step 1: Scan the ceramic panel prototype to be prepared using a 3D scanner, or directly read a DXF format drawing containing the coordinates of the closed outer boundary. Define the acquired 2D contour data as the target clipping region in the algorithm. Simultaneously determine the side length parameters of the selected hexagonal ceramic sheet, and establish a standard mathematical model of the individual ceramic sheet in the computing environment.

[0041] Step 2: Set the horizontal displacement x, vertical displacement y, and rotation angle θ of the ceramic tile array relative to the target cutting area as variables to be optimized. The values ​​of x and y are limited to the diagonal length of the hexagonal ceramic tile, and the value of θ is set to 0° to 60°.

[0042] Step 3: A genetic algorithm is used as the core computing engine. Initially, 100 individuals containing (x, y, θ) genetic information are randomly generated. The algorithm uses minimizing the total number of ceramic pieces N required to cover the target area and minimizing the total length L of the ceramic pieces cut along the target area boundary as the convergence criterion. During the iteration process, the population is continuously optimized through crossover and mutation operations. After approximately 500 generations of iteration, the algorithm converges and outputs the optimal laying parameters corresponding to the extreme value of the objective function. This scheme clarifies the specific spatial distribution coordinates of the ceramic array.

[0043] Step 4: Using computer-aided design software, construct a rectangular or irregularly shaped mold base around the target cutting area. Using the optimal layout coordinates from Step 3, generate a ceramic sheet array occupant model on the base and perform Boolean subtraction. The resulting grid positioning structure is the cavity of the limiting mold. Using fused deposition modeling (FDM) technology with polylactic acid (PLA) as the consumable material, rapidly fabricate the solid limiting mold using a 3D printer.

[0044] Step 5: On a clean workbench, first lay a layer of thermoplastic polyurethane film, then place a layer of ultra-high molecular weight polyethylene fiber cloth on top. Precisely place the 3D-printed positioning mold onto the fiber cloth. The operator or robotic arm then inserts the hexagonal ceramic pieces one by one into the mold grid. After filling, move the positioning mold vertically upwards. At this point, the ceramic pieces remain in place due to the friction of the fiber cloth surface and the adhesive effect of the film. Then, successively cover the ceramic pieces with the next layer of thermoplastic polyurethane film and ultra-high molecular weight polyethylene fiber cloth to complete the assembly of the ceramic panel prefabrication.

[0045] Step 6: Place the preform in an autoclave and set the process parameters: control the curing temperature at 150℃, apply an ambient pressure of 0.8MPa, and maintain this temperature and pressure for 120 minutes. The hot pressing process causes the adhesive film to melt and impregnate the fiber-ceramic interface, forming a high-strength, integrated ceramic panel blank after curing.

[0046] Step 7: Import the cutting path corresponding to the optimal laying scheme generated in Step 3 into the control system of the ceramic cutting machine. Because the physical layout closely matches the digital model, the cutting machine performs precise trimming along the panel boundaries. This process minimizes the amount of ceramic material cut, resulting in high cutting speed and smooth edges, ultimately yielding a high-performance, low-waste ceramic panel.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A low-loss ceramic panel preparation method based on arrangement algorithm optimization, characterized in that, Includes the following steps: Step A: Obtain two-dimensional contour data characterizing the target shape of the ceramic panel to be prepared, and construct a digital model of the target cutting area accordingly; simultaneously extract the geometric parameters of the hexagonal ceramic sheet to establish a digital model of the individual ceramic sheet; Step B: Import the target cutting area and the digital model of the individual ceramic sheet into the same two-dimensional plane space, and use the position coordinates and rotation angle of the ceramic sheet array as the core variables to perform a simulated laying operation; Step C: Introduce a layout optimization algorithm for iterative calculation. The objective functions are to minimize the number of ceramic tiles required to cover the target cutting area and to minimize the cumulative length of the ceramic tile cross-section cut by the boundary line of the target cutting area. The output is the optimal laying scheme that covers the position coordinates and arrangement angle of the ceramic tile array. Step D: Construct a digital model of the limiting mold based on the optimal laying scheme, and use rapid prototyping technology to process a physical limiting mold with a grid positioning structure, so that the grid positioning structure matches the optimal laying scheme; Step E: Lay the lower layer adhesive film and the lower layer fiber reinforcement material sequentially on the operating platform, and position the solid limiting mold on it; fill the grid positioning structure of the solid limiting mold one by one with hexagonal ceramic sheets, and remove the mold after filling is completed; then lay the upper layer adhesive film and the upper layer fiber reinforcement material sequentially on the ceramic sheet layer to obtain the ceramic panel preform. Step F: The formed ceramic panel preform is transferred to a high-temperature and high-pressure equipment for hot-pressing composite curing treatment to prepare a ceramic panel blank with the same layout as the optimal laying scheme. Step G: Retrieve the two-dimensional contour data of the ceramic panel to be prepared as a path guide, and precisely cut the ceramic panel blank along the specified trajectory to obtain the finished ceramic panel.

2. The low-loss ceramic panel preparation method based on arrangement algorithm optimization according to claim 1, characterized in that, The two-dimensional contour data of the ceramic panel to be prepared is a closed outer boundary coordinate dataset that outlines the target shape of the ceramic panel; the geometric parameters of the hexagonal ceramic sheet are the side lengths of the hexagon.

3. The low-loss ceramic panel preparation method based on arrangement algorithm optimization according to claim 1, characterized in that, The layout optimization algorithms used to perform optimization operations include genetic algorithms, particle swarm optimization, simulated annealing, or step-size search algorithms; The specific procedure for the simulated laying is as follows: the individual ceramic pieces are preset to be arranged in an array, and there is a preset gap between the individual ceramic pieces that is equal to the size of the positioning structure of the physical limiting mold grid, and the total area of ​​the generated ceramic piece array is larger than the target cutting area. The position coordinates (x, y) of the ceramic tile array relative to the target cutting area and the rotation angle θ are defined as optimization variables. Based on the arrangement optimization algorithm, iterative optimization calculation is performed in the two-dimensional plane to approximate the extreme point of the objective function.

4. The low-loss ceramic panel preparation method based on arrangement algorithm optimization according to claim 1, characterized in that, The objective function is defined as follows: the total number of ceramic pieces required to fully cover the target cutting area reaches a minimum value, and the total length of the ceramic piece cross-section cut off by the boundary line of the target cutting area reaches a minimum value.

5. The low-loss ceramic panel preparation method based on arrangement algorithm optimization according to claim 1, characterized in that, The process of constructing the digital model of the limiting mold in step D is as follows: Create a mold base model that can completely cover the target cutting area; The ceramic tile array position coordinates and rotation angle data established in the optimal laying scheme are called to generate the corresponding ceramic tile array model in digital space; Using Boolean subtraction logic, the volume occupied by the ceramic sheet array model is removed from the mold base model to obtain a two-dimensional model of the limiting mold with a grid positioning structure. The two-dimensional model is stretched along a direction perpendicular to the plane, and the stretching thickness is set to match the thickness of the hexagonal ceramic sheet to generate a three-dimensional digital model of the limiting mold.

6. The low-loss ceramic panel preparation method based on arrangement algorithm optimization according to claim 1, characterized in that, The rapid prototyping technology is selected from fused deposition modeling, stereolithography, or laser cutting; the material of the solid limiting mold is selected from polylactic acid, acrylonitrile-butadiene-styrene copolymer, photosensitive resin, nylon sheet, or polymethyl methacrylate sheet.

7. The method of claim 1, wherein the method is characterized by, The adhesive film is selected from thermoplastic polyurethane film, ethylene-vinyl acetate copolymer film, polyvinyl butyral film, or epoxy resin film; the lower fiber reinforcement material and the upper fiber reinforcement material are selected from one or more composite compositions of ultra-high molecular weight polyethylene fiber cloth, aramid fiber cloth, glass fiber cloth, or carbon fiber cloth.

8. The method of claim 1, wherein the method is a low-loss ceramic panel preparation method based on an arrangement algorithm optimization. After removing the physical limiting mold and before laying the upper layer of adhesive film, it also includes: The arrangement position of each individual ceramic sheet in the ceramic sheet array is checked, and individual ceramic sheets whose positions deviate from the preset coordinates are reset and adjusted. Gap filling material is used to fill and reinforce the gaps between the arranged ceramic tiles.

9. The method of claim 1, wherein the method is characterized by, The high-temperature and high-pressure equipment is an autoclave, and its process control parameters are set as follows: the curing temperature threshold is 120°C to 180°C, the curing pressure is 0.3MPa to 1.0MPa, and the heat preservation and pressure holding time is 60 to 180 minutes.

10. The method for low-loss fabrication of ceramic panels based on layout algorithm optimization according to claim 1, characterized in that, The cutting action in step G is carried out using a ceramic cutting machine. The cutting tool cuts through the solidified ceramic panel blank along the outline of the ceramic panel to be prepared.

Images