A molding process for carbon fiber reinforced thermoset resin matrix composites for aerospace parts manufacturing

Abstract

The present application relates to the technical field of carbon fiber preparation and composite fiber forming process field, and discloses a carbon fiber reinforced thermosetting resin matrix composite forming method for manufacturing aviation parts, which comprises the following steps: firstly, pre-oxidizing, carbonizing and surface activating polyacrylonitrile-based carbon fiber filaments, and coating epoxy sizing agent to obtain composite precursor filaments; secondly, demarcating the long filament profile and the interval of the plane curve surface trend, planning the layering track to form the overall arrangement context; collecting the layering node coordinates and classifying and tabulating them in layers, and relying on the point positions to lay various guide channels and collection cavities; setting interlayer alignment clamping and removable limiting, and fitting components, laying the annular enclosed shaping carrier reserved avoidance interval, and finally splitting the carrier and gradually removing and disassembling various auxiliary components to complete the forming pretreatment. The present application effectively improves the carbon fiber layering regularity and forming precision, reduces forming defects, and guarantees the structural stability and product consistency of aviation composite material parts.

Description

Technical Field

[0001] This invention relates to the technical field of carbon fiber preparation and composite fiber molding process, and more specifically, to a molding method for carbon fiber reinforced thermosetting resin-based composite materials used in the manufacture of aerospace parts. Background Technology

[0002] Carbon fiber reinforced thermosetting resin matrix composites are widely used in the field of aerospace component structure manufacturing due to their lightweight, high strength, fatigue resistance and excellent mechanical properties. Conventional molding methods mostly adopt simple manual lay-up, fixed trajectory arrangement and integral mold shaping processing mode, which can meet the molding and preparation requirements of basic aerospace composite component components.

[0003] In existing traditional carbon fiber composite molding processes, the filament layup lacks precise reference contour delineation and planar / curved surface orientation intervals, resulting in highly arbitrary overall filament layup arrangement and difficulty in achieving standardized and orderly laying. Furthermore, the lack of positioning methods for acquiring and storing layup node coordinates in layers makes precise control over the filament arrangement points impossible. Conventional processes often use uniformly sized flow channels, which cannot accommodate the resin flow requirements of different deviation areas, easily leading to uneven resin impregnation and molding voids. Moreover, the absence of dedicated interlayer alignment and positioning references and removable enclosure and shaping carrier structures makes layup misalignment and poor boundary molding regularity prone to occur. Traditional molding processes also lack a systematic component disassembly logic, resulting in poor consistency in the post-molding layup morphology and failing to meet the stringent manufacturing requirements of high precision, high stability, and mass standardized replication molding for aerospace components.

[0004] Therefore, it is necessary to design a molding process for carbon fiber reinforced thermosetting resin matrix composites for the manufacture of aerospace parts, in order to solve the problems of poor adaptability and positioning accuracy of layup molding, solidification of the flow guiding structure and lack of iterative correction mechanism in traditional molding technology. Summary of the Invention

[0005] In view of this, the present invention proposes a molding method for carbon fiber reinforced thermosetting resin matrix composites for the manufacture of aerospace parts, aiming to solve the problems of poor adaptability and positioning accuracy of layup molding, solidification of the flow guiding structure and lack of iterative correction mechanism in traditional molding technology.

[0006] This invention proposes a molding method for carbon fiber reinforced thermosetting resin matrix composites used in the manufacture of aerospace components, comprising: After pre-oxidation, carbonization and surface activation treatment of polyacrylonitrile-based carbon fiber precursor, it is coated with epoxy sizing agent to obtain carbon fiber reinforced thermosetting resin matrix composite precursor filament. The extension reference contour line of the precursor filament is defined, the plane and curved surface direction range of the carbon fiber filament adapted to the thermosetting resin is divided, the filament layup extension baseline in the direction range is marked, the boundary trajectory of a single layer of the carbon fiber filament is defined, and the boundary trajectory is superimposed to form the overall layup arrangement of the filament bundle. Mark all nodes of the overall layup and record the spatial coordinate data of the carbon fiber filament arrangement. Mark the reference points of the carbon fiber bundles and collect the coordinate data of the points to organize them into a layup positioning data table. Classify and store the arrangement points according to the carbon fiber filament layer. Based on the classified and stored arrangement points, various flow channels, edge diversion channels and interlayer cross channels are arranged between the filament layers. The filament bundle waste material guide channel and collection cavity are arranged and connected to the interlayer guide trough and each branch guide channel. Referring to the positions of the filament arrangement points and the flow channel, interlayer alignment locking points are set in the area avoiding the flow channel. Removable filament arrangement limiting components and bonding components are arranged, and the limiting components and bonding components are aligned with the locking points to form an interlayer alignment baseline. Define the boundary of the filament regularization and enclosure operation, and arrange the annular enclosure shaping carrier made of removable material in sections and connect them to form a closed loop, reserving a guide channel avoidance area; disassemble the annular enclosure shaping carrier along the closed loop of the carbon fiber filament, remove the limiting component, peel off the guide channel auxiliary liner, disassemble the guide channel cavity component in sequence, and peel off the filament layup edge auxiliary component layer by layer.

[0007] Furthermore, after sequentially disassembling the flow channel cavity components and peeling off the filament layup edge auxiliary components layer by layer, the process also includes: After completing the disassembly and separation of carbon fiber composite plies, the structural morphology information of each carbon fiber ply is obtained based on a three-dimensional mapping system. The molding matching level of each carbon fiber composite ply is determined based on the obtained structural morphology information. The subsequent ply layout parameters of the composite material are adjusted according to the molding matching level to determine the final ply layout reference parameters. The standardized replication ply molding operation of carbon fiber composite materials for aerospace parts is carried out based on the final ply layout reference parameters.

[0008] Furthermore, when marking the reference points of the carbon fiber bundles and collecting the coordinate data of these points to compile a layup positioning data table, and classifying and storing the arrangement points according to the layer position of the carbon fiber filaments, the process includes: A first coordinate deviation threshold and a second coordinate deviation threshold are preset, wherein the first coordinate deviation threshold is greater than the second coordinate deviation threshold; The ply positioning data table includes precise positioning data, ordinary positioning data, and deviation positioning data; The locations with coordinate deviations greater than or equal to the first coordinate deviation threshold are classified into the deviation positioning data; Points with coordinate deviations less than the first coordinate deviation threshold and greater than the second coordinate deviation threshold are classified into the ordinary positioning data. Points with coordinate deviations less than or equal to the second coordinate deviation threshold are classified into the precise positioning data.

[0009] Furthermore, when arranging various flow channels, edge distribution channels, and interlayer cross channels between filament layers according to the classified and stored arrangement points, the following is included: Obtain the ply area corresponding to the precise positioning data, normal positioning data, and deviation positioning data, and record them as the precise ply area, normal ply area, and deviation ply area, respectively. The channel layout within the precise ply area is defined as a dense layout mode, the channel layout within the ordinary ply area is defined as a conventional layout mode, and the channel layout within the deviation ply area is defined as a widened layout mode. For precise ply areas, a dense layout pattern is used to lay small, dense flow channels; for ordinary ply areas, a conventional layout pattern is used to lay standard-spacing flow channels; and for deviating ply areas, a widened layout pattern is used to lay large-diameter flow channels.

[0010] Furthermore, when setting interlayer alignment points in areas avoiding the flow channels, based on the reference filament arrangement points and the flow channel positions, this includes: A first card slot spacing standard and a second card slot spacing standard are preset, wherein the first card slot spacing standard is greater than the second card slot spacing standard; When the ply area belongs to the curved surface direction range, the interlayer alignment points are arranged according to the second positioning spacing standard; When the ply area belongs to the planar orientation interval, the interlayer alignment points are arranged according to the first positioning spacing standard. If there are stress concentration points in the plane direction section, reduce the spacing between the positioning points and increase the density of the positioning points.

[0011] Furthermore, when the annular enclosure shaping carrier made of removable material is arranged in sections and connected to form a closed loop, the process includes: A first surface curvature standard and a second surface curvature standard are preset, wherein the first surface curvature standard is greater than the second surface curvature standard; Collect the surface curvature of the boundary of the long filament regularization and enclosure operation. When the surface curvature of the boundary is greater than or equal to the first surface curvature standard, a segmented flexible connection method is used to splice the ring enclosure and shaping carrier. When the curvature of the boundary surface is less than the curvature standard of the first surface and greater than the curvature standard of the second surface, a straight and rigid connection method is used to splice the ring-shaped enclosed carrier. When the curvature of the boundary surface is less than or equal to the curvature standard of the second surface, the ring-shaped enclosure carrier is spliced ​​together using an integrated seamless connection method.

[0012] Furthermore, when acquiring the structural morphology information of each carbon fiber layup based on a 3D mapping system and determining the molding matching level of each carbon fiber layup, the following steps are included: A first-level molding matching standard, a second-level molding matching standard, and a third-level molding matching standard are preset. The molding accuracy of the first-level molding matching standard is higher than that of the second-level molding matching standard, and the molding accuracy of the second-level molding matching standard is higher than that of the third-level molding matching standard. By comparing the measured structural morphology of each carbon fiber layup with the preset benchmark layup morphology, when the morphology fit meets the first-level molding matching standard, it is classified as a high-quality molding matching level. When the shape fit meets the second-level molding matching standard but does not meet the first-level molding matching standard, it is classified as a qualified molding matching level. When the shape fit only meets the third-level molding matching standard and does not reach the second-level molding matching standard, it is classified as a molding matching level that needs to be optimized.

[0013] Furthermore, when adjusting the subsequent layup parameters of the composite material according to the molding matching grade, the following is included: If the carbon fiber layup is of the high-quality molding matching grade, then the original layup layout baseline, fiber spacing, and layup thickness parameters remain unchanged. If the carbon fiber layup is of qualified molding matching grade, adjust the fiber bundle arrangement offset angle and optimize the flow aperture of the interlayer guiding channel; If the carbon fiber layup is of an unoptimized molding matching grade, then the layup extension baseline is recalibrated, the fiber bundle arrangement points are densified, and the flow range of the edge diversion channel is expanded.

[0014] Furthermore, when performing standardized replication layup molding operations on carbon fiber composite materials for aerospace components based on the final layup layout reference parameters, the process includes: Pre-set specification standards for thin-walled parts, standard parts, and heavy-duty parts; When aerospace parts meet the specifications for thin-walled parts, a layer-by-layer replication method is adopted; When aerospace parts meet the standard specifications for conventional parts, a uniform-speed continuous layer-layout replication method is adopted. When aerospace components meet the specifications for heavy-duty components, a layered replication method is adopted, and interlayer reinforcement bonding components are added.

[0015] Furthermore, after completing the standardized replication layup molding process, it also includes: Pre-set the appearance and performance standards for the molding of aerospace parts; The composite material parts after replication molding are subjected to appearance inspection and mechanical property testing. When the parts meet both the appearance and performance qualification standards, the molding is deemed qualified and they are directly put into the warehouse for storage. When a component only meets a single qualification standard, it is judged as a defective product and undergoes local repair and optimization before a second inspection. If neither of the two qualification standards for a component is met, the molding is deemed unqualified, the layup is disassembled, and the replication molding operation is restarted.

[0016] Compared with existing technologies, the beneficial effects of this invention are as follows: First, the precursor filament is prepared by modifying and sizing polyacrylonitrile-based carbon fiber precursor. By defining the filament reference contour, dividing the flat and curved surface direction intervals, and planning the layup layout, a positioning data table is established and stored in layers by collecting the spatial coordinates of the layup. Alignment reference is constructed by combining interlayer alignment points and removable limiting bonding components, which greatly improves the positioning accuracy of carbon fiber layup and adapts to different curved and planar molding conditions. This effectively solves the problems of weak adaptability, low positioning accuracy, and easy misalignment of layup in traditional processes. At the same time, various flow channels and residual material collection cavities are arranged differently according to the point classification, breaking the traditional single solidified layout mode of flow channel structure. This adapts to the resin flow requirements of different layup areas, reduces molding defects, and ensures the regularity of layup molding by the removable enclosure shaping carrier and the step-by-step disassembly method. This provides a reliable foundation for subsequent iterative optimization of layup parameters and standardized replication molding of parts, solving the problems of solidified flow channel structure, lack of molding control and correction mechanism, and poor consistency of batch molding in traditional processes. Attached Figure Description

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A flowchart illustrating the molding process of carbon fiber reinforced thermosetting resin matrix composites for manufacturing aerospace parts, provided in an embodiment of the present invention. Detailed Implementation

[0018] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, embodiments and features in the embodiments of the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] Reference Figure 1 In some embodiments of this application, a molding method for carbon fiber reinforced thermosetting resin matrix composites used in the manufacture of aerospace parts includes the following steps: Step S100: After pre-oxidation, carbonization and surface activation treatment of polyacrylonitrile-based carbon fiber precursor, an epoxy sizing agent is coated to obtain carbon fiber reinforced thermosetting resin matrix composite precursor filament. Step S200: Delineate the extension reference contour edge of the precursor filament, divide the plane and curved surface direction range of the carbon fiber filament adapted to the thermosetting resin, mark the filament layup extension baseline within the direction range, delineate the boundary trajectory of a single layer of carbon fiber filament, and superimpose the boundary trajectories to form the overall layup arrangement of the filament bundle. Step S300: Mark all nodes of the overall layup and record the spatial coordinate data of the carbon fiber filament arrangement. Mark the reference points of the carbon fiber bundles and collect the coordinate data of the points to organize them into a layup positioning data table. Classify and store the arrangement points according to the carbon fiber filament layer. Step S400: Based on the classified and stored arrangement points, lay out various flow channels, edge diversion channels and interlayer cross channels between filament layers, lay out the filament bundle waste material guide channel and collection cavity and connect the interlayer guide trough and each branch guide channel; Step S500: Referring to the filament arrangement points and the flow channel positions, set interlayer alignment locking points in the area avoiding the flow channel, and lay out removable filament arrangement limiting components and bonding components. Align the limiting components and bonding components with the locking points to form an interlayer alignment baseline. Step S600: Delineate the boundary of the filament straightening and enclosure operation, and deploy the annular enclosure shaping carrier made of removable material in sections and connect them to form a closed loop, reserving a guide channel avoidance area; disassemble the annular enclosure shaping carrier along the closed loop of the carbon fiber filament, remove the limiting component, peel off the guide channel auxiliary liner, disassemble the guide channel cavity component in sequence, and peel off the filament layup edge auxiliary component layer by layer.

[0020] The above embodiments first modify and sizing polyacrylonitrile-based carbon fiber precursors to prepare precursor filaments. By defining the filament baseline contour, dividing the flat and curved surface direction intervals, and planning the layup layout, a positioning data table is established and stored in layers based on the collected layup spatial coordinates. Alignment references are constructed by combining interlayer alignment points and removable limiting bonding components, which significantly improves the positioning accuracy of carbon fiber layup and adapts to different curved and planar molding conditions. This effectively solves the problems of weak adaptability, low positioning accuracy, and easy misalignment of layup in traditional processes. At the same time, various flow channels and residual material collection cavities are arranged differently according to the point classification, breaking the traditional single solidified layout mode of flow channel structure. This adapts to the resin flow requirements of different layup areas, reduces molding defects, and the removable enclosure shaping carrier and step-by-step disassembly method ensure the regularity of layup molding. This provides a reliable foundation for subsequent iterative optimization of layup parameters and standardized replication molding of parts, solving the problems of solidified flow channel structure, lack of molding control and correction mechanism, and poor consistency of batch molding in traditional processes.

[0021] In a specific embodiment of this application, the above steps are implemented as follows: This molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts is adapted for the shaping, layup, and molding of irregularly shaped, variable-curvature, and multi-wall-thickness carbon fiber reinforced thermosetting resin matrix composite material parts such as aircraft fuselage skin, wing auxiliary structural components, airborne precision mounting brackets, cabin load-bearing plates, and small tail fin linings of aircraft. The specific implementation method is as follows: In the actual implementation of step S100, industrial-grade polyacrylonitrile-based carbon fiber precursor is selected and modified sequentially through a continuous pre-oxidation section, a high-temperature carbonization section, and a plasma surface activation section. An epoxy sizing agent compatible with the thermosetting resin system is uniformly coated onto the activated carbon fiber surface. After constant-temperature static curing, it is continuously wound to obtain a regular and continuous carbon fiber reinforced thermosetting resin-based composite precursor filament. In the actual implementation of step S200, based on the three-dimensional design model of aerospace components, the overall extension reference contour edge of the precursor filament is defined in the digital modeling environment. According to the curvature of the structural surface, the planar and curved orientation intervals of the carbon fiber filament, suitable for thermosetting resin impregnation and flow, are divided. Fixed extension intervals are marked within each orientation interval. The baseline for the filament layup in the development direction is established, and the closed boundary trajectory of each single layer of carbon fiber filament is marked circle by circle. Then, all single-layer boundary trajectories are superimposed on top of each other according to the layup sequence to form a complete and coherent overall filament bundle layup layout. In the actual implementation of step S300, various key layup nodes such as contour inflection points, filament bundle intersection points, and interlayer boundary points are marked on the overall layup layout. The spatial coordinate data of the carbon fiber filament layout is recorded using a three-dimensional coordinate acquisition device. The theoretical reference points of the carbon fiber bundle within the design model are calibrated, and the actual point coordinates are collected on-site and compiled into a standardized layup positioning data table. All layout points are classified, archived, and stored in strict accordance with the actual layup sequence of carbon fiber filaments from top to bottom. Step S400 is implemented in practice. During this process, the stored layout point information, which has been categorized by layer, is retrieved. Based on the distribution pattern of the point coverage area, interlayer flow channels, edge diversion channels, and interlayer cross channels are correspondingly laid out. Simultaneously, guide channels and collection cavities for guiding excess resin and filament scraps are laid out. The collection cavities are connected to each interlayer guide channel and each branch guide channel to form a fully connected guide and collection structure. In the actual implementation of step S500, the marked filament layout points and the formed guide channels are used as spatial reference benchmarks. Interlayer alignment points are set at fixed points in the layup blank area that maintains a safe distance from the guide channels. Filament layout limiting components and bonding components made of removable material are assembled. Each limiting component and bonding component is precisely aligned. The components are installed at the corresponding card positions, forming a continuous and interconnected interlayer alignment baseline. In actual implementation of step S600, the boundary of the filament regularization and enclosure operation is defined along the outermost contour of the carbon fiber filament layup. According to the difference in boundary curvature, removable annular enclosure shaping carriers are arranged in sections. They are spliced ​​together in a corresponding connection method to form a complete closed loop. A flow channel avoidance area of ​​matching size is reserved at the preset position of the carrier. After the layup is pre-shaped, the annular enclosure shaping carrier is disassembled along the outer closed loop of the carbon fiber filament. All limiting components are removed in sequence, the flow channel auxiliary liner is peeled off, the flow channel cavity components are disassembled in the order from the outside to the inside, and the filament layup edge auxiliary components are peeled off layer by layer from top to bottom to complete the entire layup shaping and auxiliary material disassembly process.

[0022] Specifically, after disassembling the flow channel cavity components in sequence and peeling off the filament layup edge auxiliary components layer by layer, the process also includes: After completing the disassembly and separation of carbon fiber composite plies, the structural morphology information of each carbon fiber ply is obtained based on a 3D mapping system. The molding matching level of each carbon fiber composite ply is determined based on the obtained structural morphology information. After adjusting the subsequent ply layout parameters of the composite material according to the molding matching level, the final ply layout reference parameters are determined. Based on the final ply layout reference parameters, standardized replication ply molding operations are carried out on the carbon fiber composite material of aerospace parts.

[0023] Specifically, the process involves the step-by-step extraction and layer-by-layer peeling of all removable limiting components, flow channel auxiliary liners, flow channel cavity components, and filament layup edge auxiliary components, ensuring that each single carbon fiber layup remains intact and independent, with no scattered displacement of the filament bundles. This completes the disassembly and separation of the carbon fiber composite layup. A structured light 3D mapping system is used as the acquisition device. This 3D mapping system is a non-contact, non-destructive scanning device adapted to the matte surface of carbon fiber, with a single-point measurement accuracy of ±0.02mm and a scanning resolution of no less than 0.1mm. It uses a fixed scanning step of 0.2mm to 0.5mm and 15° angular intervals for circumferential scanning, acquiring the contour boundary coordinates, filament arrangement center trajectory, local surface curvature, nominal thickness of a single layup, interlayer alignment reference deviation, and actual extension range of the planar and curved surfaces of each carbon fiber layup layer by layer. The number of 3D coordinate acquisition points for a single aerospace component layup is no less than 8000. Using a pre-defined standard benchmark 3D model of the layup as a comparison template, the morphological fit between the measured layup and the benchmark model is calculated using a point cloud overlap algorithm. Pre-defined threshold values ​​for forming matching level are set: morphological fit ≥ 98% is classified as Level 1 forming matching level, 95% ≤ morphological fit < 98% is classified as Level 2 forming matching level, 90% ≤ morphological fit < 95% is classified as Level 3 forming matching level, and morphological fit below 90% is marked as an abnormal layup. The fixed layup parameters include five basic parameters: layup extension baseline offset, carbon fiber tow center spacing, single-layer layup design thickness, curved section alignment and positioning spacing, and rated aperture of interlayer flow channels. The first-level forming matching grade directly uses the original complete set of layout parameters, with parameter correction offset set to 0mm. The second-level forming matching grade adjusts the tow arrangement offset angle range to 0.5°~1.5°, and the interlayer flow channel flow aperture fine-tuning range is ±0.3mm~0.8mm. The third-level forming matching grade recalibrates the layup extension baseline, with baseline correction offset controlled within 0.2mm~1.0mm, increases the tow arrangement point density by 10%~20%, and widens the radial flow range of the edge diversion channel by 5mm~12mm. The parameters after the grade adjustment are uniformly calibrated and solidified to determine the final layup layout reference parameters. The specifications for aerospace components are categorized by wall thickness: thin-walled components are ≤3mm, conventional components are 3mm < ≤10mm, and heavy-duty components are >10mm. Based on the final layup layout reference parameters, thin-walled components are replicated using a layered, independent, piece-by-piece layup replication mode, with the alignment error of a single layer controlled within ±0.1mm. Conventional components are replicated using a uniform-speed continuous layup replication mode, with the layup travel rate set at 200mm / min to 350mm / min. Heavy-duty components are replicated using a multi-layer staggered overlay layup replication mode, with interlayer reinforcement bonding components of 1.0mm to 2.0mm thickness added simultaneously. The overlap width between the components and the carbon fiber layup edge is not less than 8mm, completing the standardized replication layup molding operation of carbon fiber composite materials for aerospace components.

[0024] Understandably, the process relies on a structured light 3D mapping system to collect structural morphology data by non-contact point cloud scanning of the disassembled and separated independent single-layer carbon fiber layup. A preset standard benchmark layup model is used as a comparison template, and the molding matching level is divided according to the quantitative fit threshold. Then, the process parameters such as the layup baseline, fiber bundle arrangement, and flow channel are differentially corrected for different matching levels. The corresponding replica layup method is matched with the wall thickness specifications of aerospace parts. The parameter iteration is completed based on the actual measurement feedback data to realize the standardized replica layup molding operation of composite materials.

[0025] Specifically, when marking the reference points of carbon fiber bundles and collecting the coordinate data of these points to compile a layup positioning data table, and when classifying and storing the arrangement points according to the layer position of the carbon fiber filaments, the following steps are included: A first coordinate deviation threshold and a second coordinate deviation threshold are preset, wherein the first coordinate deviation threshold is greater than the second coordinate deviation threshold; The ply positioning data table includes precise positioning data, normal positioning data, and deviation positioning data; Points with coordinate deviations greater than or equal to the first coordinate deviation threshold are classified into deviation positioning data. Points with coordinate deviations less than the first coordinate deviation threshold and greater than the second coordinate deviation threshold are classified into ordinary positioning data. Points with coordinate deviations less than or equal to the second coordinate deviation threshold are classified into precise positioning data.

[0026] Specifically, the carbon fiber tow reference point is the theoretical reference coordinate node of the tow trajectory in the preset layup design model. The coordinate deviation is the spatial straight-line difference between the measured three-dimensional spatial coordinates of the point and the theoretical reference point. Pre-set first and second coordinate deviation thresholds with specific values ​​are used: the first threshold is set to 0.8 mm, and the second to 0.3 mm, ensuring that the first threshold is greater than the second. The layup positioning data table uses a single layer of carbon fiber filament as an independent unit, with independent filing according to layer number. The table contains six fixed fields: point number, X-axis coordinate, Y-axis coordinate, Z-axis coordinate, plane or curved surface interval, and coordinate deviation value. The data table is internally divided into three independent storage partitions, corresponding to precise positioning data, ordinary positioning data, and deviation positioning data, respectively. Using spatial straight-line deviation as the sole criterion, all filament arrangement points with measured coordinate deviation values ​​greater than or equal to 0.8 mm are uniformly categorized and stored in the deviation positioning data partition; filament arrangement points with measured coordinate deviation values ​​less than 0.8 mm and simultaneously greater than 0.3 mm are uniformly categorized and stored in the ordinary positioning data partition; and filament arrangement points with measured coordinate deviation values ​​less than or equal to 0.3 mm are uniformly categorized and stored in the precise positioning data partition. All points are archived and classified according to the actual layer position of their respective carbon fiber filaments.

[0027] Understandably, the theoretical benchmark points of carbon fiber bundles are used as a reference standard to calculate the spatial coordinate deviation of the measured arrangement points. By setting two-level gradient coordinate deviation thresholds, the bundle points are classified into different levels, and the points with different deviation levels are classified into corresponding positioning data categories. Based on the layup positioning data table, the bundle points of each layer are layered, classified, collected, and stored, thereby realizing the quantitative, hierarchical, and archived management of the bundle arrangement points.

[0028] Specifically, when arranging various flow channels, edge distribution channels, and interlayer cross channels between filament layers according to the classified storage locations, the following applies: Obtain the ply area corresponding to precise positioning data, normal positioning data, and deviation positioning data, and record them as precise ply area, normal ply area, and deviation ply area, respectively. The channel layout within the precise ply area is defined as the dense layout mode, the channel layout within the ordinary ply area is defined as the conventional layout mode, and the channel layout within the deviation ply area is defined as the widened layout mode. For precise ply areas, a dense layout pattern is used to lay small, dense flow channels; for ordinary ply areas, a conventional layout pattern is used to lay standard-spacing flow channels; and for deviating ply areas, a widened layout pattern is used to lay large-diameter flow channels.

[0029] Specifically, the interlayer flow channel of the filament is an internal channel structure for the passage of the heat-supplying solid resin medium between carbon fiber layup layers; the edge diversion channel is a resin diversion channel structure set along the outer contour edge of the layup; and the interlayer cross channel is an interconnected channel structure that transversely connects the interlayer flow channels. The precise layup area, ordinary layup area, and deviation layup area are the areas of the planar projection region of the layup formed by the bundle points corresponding to the precise positioning data, ordinary positioning data, and deviation positioning data, respectively. Using a planar projection calculation method, the planar projection areas of the layup areas covered by the precise positioning data, ordinary positioning data, and deviation positioning data are statistically calculated and labeled as precise layup area, ordinary layup area, and deviation layup area, respectively. Three fixed layout mode categories are defined: the area corresponding to the precise layup area is set as the dense layout mode, the area corresponding to the ordinary layup area is set as the conventional layout mode, and the area corresponding to the deviation layup area is set as the widened layout mode. Fixed structural parameters are set: the dense layout mode is matched with small, dense flow channels, with a channel diameter of 3mm. 5mm, with a center spacing of 15mm to 20mm; the conventional layout mode matches the standard spacing guide channel, with a channel diameter of 6mm to 8mm and a center spacing of 25mm to 30mm; the widened layout mode matches the large diameter guide channel, with a channel diameter of 9mm to 12mm and a center spacing of 35mm to 40mm; according to the size parameters of the corresponding layout mode, interlayer flow channels, edge diversion channels and interlayer cross channels of matching specifications are laid out in the precise ply area, ordinary ply area and deviation ply area areas respectively.

[0030] Understandably, the projected area of ​​the carbon fiber layup region corresponding to the positioning data of different coordinate deviation levels is first calculated separately, and the corresponding flow channel layout mode is matched for each area. Then, according to the channel specification type corresponding to each layout mode, interlayer flow channels, edge diversion channels and interlayer cross channels with different diameters and arrangements are laid out in different layup areas to achieve the zoned adaptation layout of the flow channel and the layup point deviation area.

[0031] Specifically, when setting interlayer alignment points in areas avoiding the flow channels, based on the reference filament arrangement points and the flow channel locations, this includes: A first card slot spacing standard and a second card slot spacing standard are preset, with the first card slot spacing standard being greater than the second card slot spacing standard; When the ply area belongs to the curved surface range, the interlayer alignment points are set according to the second positioning spacing standard. When the ply area is within a planar orientation zone, the interlayer alignment points are set according to the first positioning spacing standard. If there are stress concentration points in the plane direction section, reduce the spacing between the positioning points and increase the density of the positioning points.

[0032] Specifically, the interlayer alignment points are positioning reference nodes marked on the ply surface, used to define the installation positions of the removable limiting components and the bonding components; the planar orientation range is the flat ply area with a curvature of ≤5° for the extended surface of the carbon fiber filaments; the curved orientation range is the bent arc-shaped ply area with a curvature of >5° for the extended surface of the carbon fiber filaments; the stress concentration points are the filament bundle intersection nodes, ply corner nodes, and thickness abrupt change nodes that have been calibrated by finite element simulation and bear local concentrated loads. Fixed numerical standards for the alignment spacing are preset: the first alignment spacing standard is set to 18mm~22mm, and the second alignment spacing standard is set to 10mm~14mm, ensuring that the first alignment spacing standard is greater than the second alignment spacing standard. Based on the filament orientation interval division results, in the curved orientation interval, interlayer alignment points are evenly distributed at a fixed interval of 10mm to 14mm; in the planar orientation interval, interlayer alignment points are evenly distributed at a fixed interval of 18mm to 22mm; the stress concentration points already marked in the planar orientation interval are selected, and the spacing of the points in this area is reduced by 35% based on the first standard spacing, and the interlayer alignment points are densely distributed. All points are placed at a safe clearance distance of not less than 4mm from the edge of the flow channel.

[0033] Understandably, by combining the spatial location of the carbon fiber bundle arrangement points with the flow channel and making avoidance settings, and by setting two different positioning spacing standards, the interlayer alignment positioning points are arranged according to the corresponding spacing of the plane or curved surface range to which the layup belongs. At the same time, the stress concentration points in the plane range are densified by reducing the positioning spacing, so as to achieve the differentiated and regular arrangement of the alignment positioning points according to the layup area type.

[0034] Specifically, when arranging removable material into ring-shaped enclosures and connecting them to form closed loops, the following is included: A first surface curvature standard and a second surface curvature standard are preset, with the first surface curvature standard being greater than the second surface curvature standard; Collect the surface curvature of the boundary of the long filament regularization enclosure operation. When the surface curvature of the boundary is greater than or equal to the first surface curvature standard, a segmented flexible connection method is used to splice the ring enclosure shaping carrier. When the curvature of the boundary surface is less than the curvature standard of the first surface but greater than the curvature standard of the second surface, a straight and rigid connection method is used to splice the ring-shaped enclosed carrier. When the curvature of the boundary surface is less than or equal to the curvature standard of the second surface, a seamless, integrated method is used to splice the ring-shaped enclosure carrier.

[0035] Specifically, the annular enclosure shaping carrier is a ring-shaped component made of water-soluble or low-temperature fusible removable polymer material, used to define the outer contour of the carbon fiber filament layup; the boundary of the filament alignment enclosure operation is the closed edge contour line formed by the outermost contour of the carbon fiber filament layup; the surface curvature is a parameter corresponding to the degree of bending per unit arc length of the enclosure boundary contour line. A pre-set quantitative curvature threshold is used, with the first surface curvature standard set at 0.08 mm⁻¹ and the second surface curvature standard set at 0.03 mm⁻¹, ensuring that the first surface curvature standard value is greater than the second surface curvature standard value; a three-dimensional contour scanning device is used to continuously collect surface curvature parameters at multiple points along the boundary of the filament alignment enclosure operation, and the average value is taken as the actual curvature value of the boundary. When the curvature of the boundary surface is greater than or equal to 0.08 mm⁻¹, the annular enclosure carrier is divided into multiple independent arc-shaped units, which are connected by a flexible hinge structure and spliced ​​together in a segmented flexible connection manner. When the curvature of the boundary surface is less than 0.08 mm⁻¹ but greater than 0.03 mm⁻¹, standard rigid straight segment carrier units are used, which are connected by an end slot fitting structure and spliced ​​together in a straight rigid connection manner. When the curvature of the boundary surface is less than or equal to 0.03 mm⁻¹, an integrally molded annular component is used without segmented splitting structure, and a closed loop is directly formed in an integral seamless connection manner. During the deployment process, a fixed-size guide channel avoidance zone is reserved at the corresponding position.

[0036] Understandably, by pre-setting two-level gradient surface curvature judgment standards, the actual surface curvature values ​​of the carbon fiber filament enclosure operation boundary are collected, and three different connection forms—segmented flexibility, straight rigidity, and integrated seamless—are matched according to the actual curvature interval to complete the adaptation and splicing of the ring enclosure shaping carrier and construct a complete closed loop.

[0037] Specifically, when acquiring the structural morphology information of each carbon fiber layup based on a 3D mapping system and determining the molding matching level of each carbon fiber layup, the following is included: First-level molding matching standard, second-level molding matching standard and third-level molding matching standard are preset. The molding accuracy of the first-level molding matching standard is higher than that of the second-level molding matching standard, and the molding accuracy of the second-level molding matching standard is higher than that of the third-level molding matching standard. By comparing the measured structural morphology of each carbon fiber layup with the preset benchmark layup morphology, when the morphology fit meets the first-level molding matching standard, it is classified as a high-quality molding matching level. When the shape fit meets the second-level molding matching standard but does not meet the first-level molding matching standard, it is classified as a qualified molding matching level. When the shape fit only meets the third-level molding matching standard and does not reach the second-level molding matching standard, it is classified as a molding matching level that needs to be optimized.

[0038] Specifically, the 3D mapping system is a non-contact structured light 3D scanning acquisition device used to non-destructively acquire 3D point cloud data of carbon fiber layup. The structural morphology information includes a 3D point cloud dataset containing the coordinates of the carbon fiber layup contour boundaries, the trajectory of the fiber bundle arrangement, the curvature of local surfaces, the thickness of a single layup layer, and the edge extension range. The preset benchmark layup morphology is a pre-constructed 3D digital model of a standard carbon fiber layup based on the design parameters of aerospace components. The morphology fit is the percentage of spatial overlap between the measured layup point cloud and the benchmark layup model point cloud, quantified as a percentage. A three-level morphology fit threshold is pre-set in gradients: 98% for the first-level standard, 92% for the second-level standard, and 85% for the third-level standard. The precision of the morphology fit standard decreases sequentially from level one to level three. A 3D mapping system was used to perform a full-coverage scan of each carbon fiber layup, completely collecting the structural morphology information of each layup. The measured layup point cloud data was then compared point-to-point with the preset benchmark layup morphology model to calculate the corresponding morphology fit value. When the morphology fit was greater than or equal to 98%, the corresponding layup was classified as a high-quality molding match level. When the morphology fit was greater than or equal to 92% and less than 98%, the corresponding layup was classified as a qualified molding match level. When the morphology fit was greater than or equal to 85% and less than 92%, the corresponding layup was classified as a molding match level that needs optimization.

[0039] Understandably, a three-level molding matching judgment standard with progressively decreasing accuracy is pre-set. The actual structural morphology of the carbon fiber layup is collected through a three-dimensional mapping system. The measured layup morphology is compared and verified with the preset benchmark layup morphology. Based on the different standard ranges of the morphology fit, three molding matching levels are correspondingly divided: excellent, qualified, and needing optimization.

[0040] Specifically, when adjusting the subsequent layup parameters of the composite material according to the molding matching grade, the following are included: If the carbon fiber layup is of the high-quality molding matching grade, then the original layup layout baseline, fiber spacing, and layup thickness parameters remain unchanged. If the carbon fiber layup is of qualified molding matching grade, adjust the fiber bundle arrangement offset angle and optimize the flow aperture of the interlayer guiding channel; If the carbon fiber layup is of an unoptimized molding matching grade, then the layup extension baseline is recalibrated, the fiber bundle arrangement points are densified, and the flow range of the edge diversion channel is expanded.

[0041] Specifically, the layup baseline is the reference outline of the initial extension of the single-layer carbon fiber filament layup; the filament spacing is the straight-line spacing between the central axes of adjacent carbon fiber filament bundles; the layup thickness is the vertical nominal thickness of a single-layer carbon fiber layup; the filament bundle offset angle is the angle between the actual extension direction of the filament bundle and the layup baseline; the flow orifice diameter of the interlayer flow channel is the equivalent inner diameter of the flow cross section of the interlayer flow channel; the layup extension baseline correction is the coordinate offset correction of the original reference outline; the filament bundle layout point densification is the increase in the number of reference points per unit layup area; and the edge diversion channel flow range is the radial extension width of the channel along the edge of the layup. If the carbon fiber layup is of high quality molding matching grade, the initial layup layout baseline coordinates, standard filament spacing, and single-layer design layup thickness are used without any numerical adjustments or coordinate changes to any process parameters. If the carbon fiber layup is of qualified molding matching grade, the filament arrangement offset angle is finely adjusted within the range of 0.6° to 1.8°, and the flow aperture of the interlayer guide channel is corrected for size adaptation within the range of ±0.4mm to 0.9mm. If the carbon fiber layup is of molding matching grade to be optimized, the layup extension baseline is corrected by a coordinate offset of 0.3mm to 1.2mm, the filament arrangement points are densified by 12% to 25% on the basis of the original points, and the radial guide range of the edge diversion channel is widened outward by 6mm to 15mm.

[0042] Understandably, based on the different molding matching grades of carbon fiber layup, graded parameter control is implemented. The superior grade directly uses the original layup layout baseline, filament spacing and layup thickness parameters. The qualified grade makes targeted fine adjustments to the filament layout offset angle and the flow aperture of the interlayer guiding channel. The grade to be optimized corrects the layup extension baseline, densifies the filament layout points and widens the flow range of the edge diversion channel, so as to achieve graded differentiated adjustment of layup layout parameters.

[0043] Specifically, when performing standardized replication layup molding operations on carbon fiber composite materials for aerospace components based on the final layup layout reference parameters, the following are included: Pre-set specification standards for thin-walled parts, standard parts, and heavy-duty parts; When aerospace parts meet the specifications for thin-walled parts, a layer-by-layer replication method is adopted; When aerospace parts meet the standard specifications for conventional parts, a uniform-speed continuous layer-layout replication method is adopted. When aerospace components meet the specifications for heavy-duty components, a layered replication method is adopted, and interlayer reinforcement bonding components are added.

[0044] Specifically, the component wall thickness refers to the solid thickness of the vertical cross-section of the substrate after the aerospace component is formed; the layered layup replication method is a process in which only a single layer of carbon fiber bundle is laid at a time, with intermittent layer-by-layer operations; the uniform-speed continuous layup replication method is a process in which multiple layers of carbon fiber bundles are laid continuously at a constant feed speed; the superimposed layup replication method is a process in which multiple layers of bundles are stacked simultaneously to complete the layup; the interlayer reinforcement bonding component is a sheet-like auxiliary bonding connector made of removable rigid resin material. A pre-defined standard for determining component wall thickness is established: components with a wall thickness ≤ 3.0 mm are classified as thin-walled components, components with a wall thickness < 3.0 mm ≤ 10.0 mm are classified as conventional components, and components with a wall thickness > 10.0 mm are classified as heavy-duty components. When the aerospace component is a thin-walled component, a layered layup replication method is adopted, with a pause of 3 to 6 seconds after each layer is laid, and the alignment and calibration error of each layer is controlled within ±0.10 mm. When the aerospace component is a conventional component, a uniform speed continuous layup replication method is adopted, with the filament feed speed constantly set to 210 mm / min to 340 mm / min. When the aerospace component is a heavy component, a superimposed layup replication method is adopted, with 2 to 4 layers stacked at a time, and interlayer reinforcement bonding components with a thickness of 1.5 mm to 2.5 mm are added, with the overlap width between the components and the carbon fiber layup edge set to 9 mm to 14 mm.

[0045] Understandably, the three categories of specifications corresponding to the wall thickness of aerospace components are pre-defined. Based on the final determined layup layout benchmark parameters, the replication molding methods of layered layup, uniform continuous layup, and superimposed layup are matched according to the specification category of the component. For heavy components, interlayer reinforcement bonding components are added on the basis of superimposed layup to realize the classification and standardized replication molding of carbon fiber composite material layup.

[0046] Specifically, after completing the standardized replication layup process, it also includes: Pre-set the appearance and performance standards for the molding of aerospace parts; The composite material parts after replication molding are subjected to appearance inspection and mechanical property testing. When the parts meet both the appearance and performance qualification standards, the molding is deemed qualified and they are directly put into the warehouse for storage. When a component only meets a single qualification standard, it is judged as a defective product and undergoes local repair and optimization before a second inspection. If neither of the two qualification standards for a component is met, the molding is deemed unqualified, the layup is disassembled, and the replication molding operation is restarted.

[0047] Specifically, the acceptable standards for molded appearance are quantitative indicators of the surface morphology, boundary dimensions, and layup morphology of aerospace carbon fiber composite parts; the acceptable standards for molded performance are physical performance indicators of the mechanical load-bearing capacity and interlayer bonding of aerospace carbon fiber composite parts; molded defective products are molded components that meet the standard in one inspection dimension but fail to reach the threshold in another inspection dimension; molded unqualified products are molded components that fail to meet the set thresholds in both appearance and performance inspections. Pre-set quantitative judgment standards are as follows: acceptable appearance standards: surface porosity ≤ 1.2%, maximum fiber bundle offset ≤ 0.2 mm, layup edge straightness error ≤ 0.15 mm, no continuous scratches on the surface; acceptable performance standards: interlayer shear strength ≥ 52 MPa, room temperature tensile strength ≥ 1550 MPa, flexural modulus ≥ 135 GPa. High-definition industrial inspection cameras are used to scan and inspect the appearance, while a microcomputer-controlled electronic universal testing machine is used to test the mechanical properties at room temperature. When a part meets both the appearance and performance standards for molding, it is judged as a qualified molding component, and a batch number is affixed before it is stored in the warehouse. When a part only meets one of the appearance or performance standards, it is judged as a defective product. The defective area is repaired by local grinding, wire splicing, and glue application before being sent to the inspection station for a second inspection. When neither the appearance nor the performance indicators of a part meet the preset standards, it is judged as a non-qualified molding component. All carbon fiber layers are disassembled using a low-temperature heating peeling method, and residual matrix resin is removed before the replication molding process is restarted.

[0048] Understandably, by pre-setting two qualification standards for the molding appearance and molding performance of aerospace composite material parts, the replica molded components are simultaneously tested in both appearance and mechanical properties. Based on the compliance of the two standards, they are divided into three levels: qualified, defective, and unqualified, and respectively, a graded disposal process is implemented, including direct warehousing, partial repair and re-inspection, and disassembly and re-replicating.

[0049] In a specific embodiment of this application, the above steps are implemented as follows: This method is applicable to the mass production of carbon fiber reinforced thermosetting resin matrix composite parts with different configurations and wall thicknesses, such as aircraft fuselage skin, wing accessories, cabin load-bearing structures, and airborne precision supports; during implementation, steps S100 to S600 are strictly followed sequentially, first completing the modification treatment and sizing of polyacrylonitrile-based carbon fiber precursor to prepare precursor filaments, and then comprehensively planning the filament extension profile, planar and curved surface orientation range, and layup pattern. Then, coordinates of the reference points of the filament bundle are collected, classified and categorized, and a layup positioning data table is established. Based on the level of point deviation, different specifications of interlayer flow channels, edge diversion channels and interlayer cross channels are laid out in different areas. The interlayer alignment points are laid out in a differentiated manner according to the characteristics of the layup plane, curved surface interval and stress distribution, and the interlayer alignment reference is established. Then, according to the curvature of the enclosing boundary surface, the corresponding connection method is matched to assemble the ring-shaped enclosing shaping carrier to form a closed ring layer. After the layup shaping is completed, the carrier is disassembled in sequence, the limiting components are removed, and the auxiliary lining and edge auxiliary components are peeled off. After the components are disassembled and separated, a structured light 3D mapping system is used to scan and collect structural morphology information of each single layer of carbon fiber layup in all dimensions. Combined with the morphological fit of the preset benchmark layup model, three levels of molding matching are divided. Different parameter adjustment methods are adopted for different levels, including parameter retention, minor fine-tuning, baseline correction and point densification, to solidify a unified layup layout benchmark parameter. Then, according to the wall thickness of aerospace parts, three specifications are divided into thin-walled, conventional and heavy-duty, and respectively matched with layer-by-layer layup, uniform continuous layup and multi-layer superimposed layup replication molding mode. For heavy-duty parts, interlayer reinforcement bonding components are added. After the standardized replication molding is completed, two-dimensional inspection is carried out based on the preset quantitative qualification standards of appearance and mechanical properties. The whole process quality control is completed by graded disposal method of qualified warehousing, defect repair and re-inspection, and unqualified disassembly and remanufacturing. The whole process can be adapted to the standardized and iterative molding operation of aerospace carbon fiber composite material parts with different surface curvature, different layup complexity and different wall thickness.

[0050] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program goods. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program goods embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0051] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program goods according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0052] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0053] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A molding method for carbon fiber reinforced thermosetting resin-based composite materials used in the manufacture of aerospace parts, characterized in that, include: After pre-oxidation, carbonization and surface activation treatment of polyacrylonitrile-based carbon fiber precursor, it is coated with epoxy sizing agent to obtain carbon fiber reinforced thermosetting resin matrix composite precursor filament. The extension reference contour line of the precursor filament is defined, the plane and curved surface direction range of the carbon fiber filament adapted to the thermosetting resin is divided, the filament layup extension baseline in the direction range is marked, the boundary trajectory of a single layer of the carbon fiber filament is defined, and the boundary trajectory is superimposed to form the overall layup arrangement of the filament bundle. Mark all nodes of the overall layup and record the spatial coordinate data of the carbon fiber filament arrangement. Mark the reference points of the carbon fiber bundles and collect the coordinate data of the points to organize them into a layup positioning data table. Classify and store the arrangement points according to the carbon fiber filament layer. Based on the classified and stored arrangement points, various flow channels, edge diversion channels and interlayer cross channels are arranged between the filament layers. The filament bundle waste material guide channel and collection cavity are arranged and connected to the interlayer guide trough and each branch guide channel. Referring to the positions of the filament arrangement points and the flow channel, interlayer alignment locking points are set in the area avoiding the flow channel. Removable filament arrangement limiting components and bonding components are arranged, and the limiting components and bonding components are aligned with the locking points to form an interlayer alignment baseline. Define the boundary of the filament regularization and enclosure operation, and arrange the annular enclosure shaping carrier made of removable material in sections and connect them to form a closed loop, reserving a guide channel avoidance area; disassemble the annular enclosure shaping carrier along the closed loop of the carbon fiber filament, remove the limiting component, peel off the guide channel auxiliary liner, disassemble the guide channel cavity component in sequence, and peel off the filament layup edge auxiliary component layer by layer.

2. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 1, characterized in that, After disassembling the flow channel cavity components in sequence and peeling off the auxiliary components at the edge of the filament layup layer by layer, the process also includes: After completing the disassembly and separation of carbon fiber composite plies, the structural morphology information of each carbon fiber ply is obtained based on a three-dimensional mapping system. The molding matching level of each carbon fiber composite ply is determined based on the obtained structural morphology information. The subsequent ply layout parameters of the composite material are adjusted according to the molding matching level to determine the final ply layout reference parameters. The standardized replication ply molding operation of carbon fiber composite materials for aerospace parts is carried out based on the final ply layout reference parameters.

3. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 1, characterized in that, When marking the reference points of the carbon fiber bundles and collecting the coordinate data of these points to compile a layup positioning data table, and categorizing and storing the arrangement points according to the layer position of the carbon fiber filaments, the following steps are included: A first coordinate deviation threshold and a second coordinate deviation threshold are preset, wherein the first coordinate deviation threshold is greater than the second coordinate deviation threshold; The ply positioning data table includes precise positioning data, ordinary positioning data, and deviation positioning data; The locations with coordinate deviations greater than or equal to the first coordinate deviation threshold are classified into the deviation positioning data; Points with coordinate deviations less than the first coordinate deviation threshold and greater than the second coordinate deviation threshold are classified into the ordinary positioning data. Points with coordinate deviations less than or equal to the second coordinate deviation threshold are classified into the precise positioning data.

4. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 3, characterized in that, When arranging various flow channels, edge distribution channels, and interlayer cross channels between filament layers according to the classified and stored layout points, the following are included: Obtain the ply area corresponding to the precise positioning data, normal positioning data, and deviation positioning data, and record them as the precise ply area, normal ply area, and deviation ply area, respectively. The channel layout within the precise ply area is defined as a dense layout mode, the channel layout within the ordinary ply area is defined as a conventional layout mode, and the channel layout within the deviation ply area is defined as a widened layout mode. For precise ply areas, a dense layout pattern is used to lay small, dense flow channels; for ordinary ply areas, a conventional layout pattern is used to lay standard-spacing flow channels; and for deviating ply areas, a widened layout pattern is used to lay large-diameter flow channels.

5. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 4, characterized in that, When setting interlayer alignment points in areas avoiding the flow channels, based on the reference filament arrangement points and flow channel locations, the following are included: A first card slot spacing standard and a second card slot spacing standard are preset, wherein the first card slot spacing standard is greater than the second card slot spacing standard; When the ply area belongs to the curved surface direction range, the interlayer alignment points are arranged according to the second positioning spacing standard; When the ply area belongs to the planar orientation interval, the interlayer alignment points are arranged according to the first positioning spacing standard. If there are stress concentration points in the plane direction section, reduce the spacing between the positioning points and increase the density of the positioning points.

6. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 5, characterized in that, When the annular enclosure shaping carrier made of removable material is arranged in sections and connected to form a closed loop, the following steps are included: A first surface curvature standard and a second surface curvature standard are preset, wherein the first surface curvature standard is greater than the second surface curvature standard; Collect the surface curvature of the boundary of the long filament regularization and enclosure operation. When the surface curvature of the boundary is greater than or equal to the first surface curvature standard, a segmented flexible connection method is used to splice the ring enclosure and shaping carrier. When the curvature of the boundary surface is less than the curvature standard of the first surface and greater than the curvature standard of the second surface, a straight and rigid connection method is used to splice the ring-shaped enclosed carrier. When the curvature of the boundary surface is less than or equal to the curvature standard of the second surface, the ring-shaped enclosure carrier is spliced ​​together using an integrated seamless connection method.

7. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 2, characterized in that, When acquiring structural morphology information of each carbon fiber layup based on a 3D mapping system and determining the molding matching level of each carbon fiber layup, the following is included: A first-level molding matching standard, a second-level molding matching standard, and a third-level molding matching standard are preset. The molding accuracy of the first-level molding matching standard is higher than that of the second-level molding matching standard, and the molding accuracy of the second-level molding matching standard is higher than that of the third-level molding matching standard. By comparing the measured structural morphology of each carbon fiber layup with the preset benchmark layup morphology, when the morphology fit meets the first-level molding matching standard, it is classified as a high-quality molding matching level. When the shape fit meets the second-level molding matching standard but does not meet the first-level molding matching standard, it is classified as a qualified molding matching level. When the shape fit only meets the third-level molding matching standard and does not reach the second-level molding matching standard, it is classified as a molding matching level that needs to be optimized.

8. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 7, characterized in that, When adjusting the subsequent layup parameters of the composite material according to the molding matching grade, the following are included: If the carbon fiber layup is of the high-quality molding matching grade, then the original layup layout baseline, fiber spacing, and layup thickness parameters remain unchanged. If the carbon fiber layup is of qualified molding matching grade, adjust the fiber bundle arrangement offset angle and optimize the flow aperture of the interlayer guiding channel; If the carbon fiber layup is of an unoptimized molding matching grade, then the layup extension baseline is recalibrated, the fiber bundle arrangement points are densified, and the flow range of the edge diversion channel is expanded.

9. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 8, characterized in that, When performing standardized replication layup molding operations on carbon fiber composite materials for aerospace components based on the final layup layout reference parameters, the following are included: Pre-set specification standards for thin-walled parts, standard parts, and heavy-duty parts; When aerospace parts meet the specifications for thin-walled parts, a layer-by-layer replication method is adopted; When aerospace parts meet the standard specifications for conventional parts, a uniform-speed continuous layer-layout replication method is adopted. When aerospace components meet the specifications for heavy-duty components, a layered replication method is adopted, and interlayer reinforcement bonding components are added.

10. The molding method for carbon fiber reinforced thermosetting resin matrix composite materials used in the manufacture of aerospace parts according to claim 9, characterized in that, After completing the standardized replica layup process, the following is also included: Pre-set the appearance and performance standards for the molding of aerospace parts; The composite material parts after replication molding are subjected to appearance inspection and mechanical property testing. When the parts meet both the appearance and performance qualification standards, the molding is deemed qualified and they are directly put into the warehouse for storage. When a component only meets a single qualification standard, it is judged as a defective product and undergoes local repair and optimization before a second inspection. If neither of the two qualification standards for a component is met, the molding is deemed unqualified, the layup is disassembled, and the replication molding operation is restarted.

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