Hot torch auxiliary roll forming equipment for fiber metal hybrid laminate

Abstract

The utility model discloses hot torch auxiliary roll forming equipment for a fiber metal hybrid laminate, which belongs to the technical field of preparation and forming of composite materials and comprises a discharging part, a hot melting part, a molding part, a cooling shaping part and a plurality of layered plates. One ends of the plurality of plate materials are converged and then penetrate out of the discharging part, the hot melting part, the molding part and the cooling shaping part which are connected in sequence; the molding part comprises a plurality of forming rollers arranged on the upper sides and the lower sides of the plates at equal intervals, hot torch guns are correspondingly arranged on the sides, close to the hot melting part, of the multiple forming rollers, and the hot torch guns are arranged on the upper end face after the multiple plates are converged. The problems of low formability, interlayer failure or insufficient interlayer performance and the like of the fiber metal heterogeneous laminates in the collaborative processing process are effectively solved through a continuous progressive roll forming and hot torch auxiliary technology, the preparation process is continuous and simple, the preparation period is short, the cost is low, additional operation is not needed, and the method is suitable for large-scale production.

Description

Technical Field

[0001] This utility model belongs to the field of composite material preparation and forming technology, specifically relating to a torch-assisted roll forming equipment for fiber-metal hybrid laminates. Background Technology

[0002] Fiber-Metal Laminates (FMLs) are hybrid composite materials formed by alternating layers of thin metal sheets and fiber materials, cured under specific temperature and pressure. FMLs combine the characteristics of traditional fiber composites and metal materials, overcoming the shortcomings of single composite materials and metal materials. They possess not only high specific strength and specific stiffness but also the toughness and processability of metal materials. Excellent fatigue performance and damage tolerance are the most prominent features of FMLs. High-performance FML components can have their layup sequence optimized according to load-bearing requirements, combining high specific strength, high stiffness, and excellent fatigue resistance and damage tolerance, making them an ideal choice for lightweight transportation vehicles. In recent years, the application of thermoplastic polymer-based FMLs has grown rapidly due to their recyclability, shorter molding cycle, and excellent toughness.

[0003] Traditional thermosetting fiber-metal hybrid laminates employ autoclave self-forming processes, which are time-consuming and costly, limiting mass production of these components. While there are existing cases of directly processing thermoplastic fiber-metal laminates using mature metal forming processes such as hot stamping, shot peening, and progressive sheet forming, which have improved process efficiency and reduced costs to some extent, they still face forming defects such as fiber buckling and breakage, matrix cracking, interlayer delamination, and delayed cracking. Furthermore, the complex and discontinuous layup and forming processes continue to restrict the large-scale application of fiber-metal hybrid laminate structures.

[0004] Existing technologies disclose some patents for production equipment of fiber-reinforced thermoplastic composite panels. Among them, invention patent with publication number CN114701217A discloses a method for preparing continuous fiber-reinforced thermoplastic composite panels. A steel plate is placed on the left side of a roller pressing device, and a steel plate heating device preheats the steel plate, preheating the adhesive film to a molten state. The roller pressing device presses and cools the composite structure to quickly bond the molten adhesive film to the surface of the steel plate or honeycomb core. A composite machine is used to heat, press, and cool the surface layer of the composite structure to form the continuous fiber-reinforced thermoplastic composite panel. Although this method solves the problem of uneven bonding strength due to the inability to selectively heat different areas of the board, it still faces problems such as fiber buckling and breakage, matrix cracking, interlayer delamination, and delayed cracking, as well as complex and discontinuous layup and forming processes, hindering large-scale application.

[0005] Therefore, there is an urgent need for a high-efficiency, continuous, and low-cost integrated rapid prototyping equipment for fiber-metal laminates. Utility Model Content

[0006] To overcome the problems of existing technologies, such as fiber buckling and breakage, matrix cracking, interlayer delamination, and delayed cracking, as well as the complex and discontinuous layup and forming processes that prevent large-scale application, this utility model provides a torch-assisted roll forming device for fiber-metal hybrid laminates. The device includes a feeding section, a hot-melting section, a molding section, a cooling and shaping section, and several layers of sheet metal. The sheets converge at one end and exit through the sequentially connected feeding section, hot-melting section, molding section, and cooling and shaping section. The molding section includes several forming rollers equidistantly arranged on the upper and lower sides of the sheet metal. Each forming roller has a torch gun positioned on the side closest to the hot-melting section, and the torch gun is located on the upper surface of the converged sheet metal layers.

[0007] Furthermore, the material feeding section includes a laying controller, and several of the sheet materials are respectively disposed on the left side of the laying controller, and the several sheet materials converge and pass through the laying controller.

[0008] Furthermore, the forming roller includes a grooved roller and a smooth roller. The grooved roller and the smooth roller are symmetrically arranged on both sides of the sheet and are in contact with the upper and lower end faces of the sheet. After the sheet passes through a number of grooved rollers and smooth rollers arranged vertically, a groove is formed. The depth of the groove formed by each grooved roller and smooth roller is progressively increased.

[0009] Furthermore, the hot-melting section includes an infrared heating furnace, the heating temperature of which is 20°C higher than the melting point of the uppermost sheet material.

[0010] Furthermore, hot-pressing lay-up rollers are symmetrically arranged on both sides of the sheet material at the outlet end of the infrared heating furnace, and the hot-pressing lay-up rollers are arranged close to the infrared heating furnace.

[0011] Furthermore, the cooling and shaping section includes an in-situ annealing component and a cooling and shaping roller positioned behind the in-situ annealing component, wherein the cooling and shaping roller is in contact with the upper and lower end faces of the sheet material.

[0012] Furthermore, the roll gap pressure of the hot-pressed layup roll is 1~1.5MPa.

[0013] Furthermore, the sheet materials, from top to bottom, include thermoplastic woven carbon fiber prepreg, thermoplastic film, and metal sheet.

[0014] Furthermore, the layup controller, forming roll, and cooling and shaping roll are controlled by the controller to adjust the up and down movement of the rolling roll, and the controller is electrically connected to the layup controller, forming roll, and cooling and shaping roll.

[0015] The beneficial effects of adopting the technical solution of this utility model are as follows:

[0016] (1) By using continuous progressive hot torch-assisted roll forming and in-situ annealing, the problems of low formability, interlayer failure, or insufficient interlayer performance during the co-processing of fiber-metal heterogeneous laminates are solved. Continuous layup rolls, multi-component forming rolls with different cross-sections, and cooling and consolidation rolls after infrared annealing heat treatment are used to achieve progressive continuous deformation of the laminate from layup to the final shaped cross-section. The preparation process is continuous and simple, with a short preparation cycle and low cost, and requires no additional operations, making it suitable for large-scale production.

[0017] (2) By designing the forming angle distribution of the forming roll section and in-situ heating with a hot torch, the fluidity of the fiber in the forming area is significantly improved, the formability of the layer is enhanced, and the risk of fiber kinking and cracking and matrix cracking is reduced.

[0018] (3) By adding in-situ annealing components and cooling and shaping rollers, the interfacial transfer and penetration time within the resin layer is extended, the cooling rate of the thermally-property resin is reduced, the crystallinity is increased, and the interlayer residual stress is reduced, thereby improving the overall mechanical properties of the roll-formed fiber-metal hybrid structure. Setting up several continuous forming rollers eliminates the need for an autoclave process, which can improve the efficiency of large-scale production and reduce the preparation time. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a torch-assisted roll forming equipment for a fiber-metal hybrid laminate according to this utility model;

[0021] In the diagram, 1. Molding section; 2. Cooling and shaping section; 3. Sheet material; 4. Forming roller; 5. Hot torch; 6. Laying controller; 7. Infrared heating furnace; 8. Hot press layup roller; 9. In-situ annealed part; 10. Cooling and shaping roller; 11. Thermoplastic woven carbon fiber prepreg; 12. Thermoplastic film; 13. Metal sheet. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Therefore, the following detailed description of the embodiments of this utility model provided in the accompanying drawings is not intended to limit the scope of the claimed utility model, but merely to represent selected embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0023] This embodiment solves the problems of low formability, interlayer failure, or insufficient interlayer performance in the co-processing of fiber-metal heterogeneous laminates by using continuous progressive hot-torch assisted roll forming and in-situ annealing. It employs continuous layup rolls, multi-component forming rolls with different cross-sections, and infrared annealing. Through continuous progressive roll forming and hot-torch assisted technology, it effectively solves the problems of low formability, interlayer failure, or insufficient interlayer performance faced by fiber-metal heterogeneous laminates in the co-processing process. The cooling and consolidation rolls after heat treatment achieve progressive continuous deformation of the laminate from layup to the final shaped cross-section. The manufacturing process is continuous and simple, with a short preparation cycle, low cost, and requires no additional operations, making it suitable for large-scale production. Specific implementation methods are as follows:

[0024] Reference Figure 1 As shown, a torch-assisted roll forming device for fiber-metal hybrid laminate includes a feeding section, a hot melting section, a molding section 1, a cooling and shaping section 2, and several layers of sheet materials 3. The sheets of sheet materials 3 converge at one end and then pass through the feeding section, hot melting section, molding section 1, and cooling and shaping section 2 connected in sequence. The molding section 1 includes several forming rollers 4 equidistantly arranged on the upper and lower sides of the sheet materials 3. Each of the forming rollers 4 is provided with a torch gun 5 on the side of the forming rollers 4 near the hot melting section, and the torch gun 5 is placed on the upper end face of the converged sheet materials 3.

[0025] Here, continuous deformation to the final shape is achieved through multiple sets of forming rollers 4 with different cross-sections. A temperature-controlled heat torch 5 is positioned above the sheet material 3, heating the local fibers within each shaping area to improve fiber flowability at the forming rounded corners, enhance the formability of the laminate, and reduce the risk of fiber kinking and breakage and matrix cracking. This achieves integrated fabrication of rapid continuous layup, rapid heating and welding, progressive synergistic deformation, and recrystallization curing of the laminate, ensuring a smooth and continuous transition from the initial material strip to the final solidified structural shape, and enabling the large-scale application of high-performance fiber-metal hybrid structures.

[0026] In a preferred embodiment, the material feeding section includes a laying controller 6, with several plates 3 respectively disposed on the left side of the laying controller 6, and the plates 3 passing through the laying controller 6 after converging.

[0027] Here, several sheets 3 are stacked from top to bottom and then fed into the laying controller 6. The laying controller 6 presses the sheets 3 together, and the laying speed of the sheets 3 can be adjusted according to actual production needs.

[0028] In a preferred embodiment, the forming roller 4 includes a grooved roller and a smooth roller. The grooved roller and the smooth roller are symmetrically arranged on both sides of the sheet 3 and are in contact with the upper and lower end faces of the sheet 3. After the sheet 3 passes through a number of grooved rollers and smooth rollers arranged vertically, a groove is formed. The depth of the groove formed by each grooved roller and smooth roller is successively increased.

[0029] Here, a groove structure is formed when the sheet 3 passes through the grooved and smooth rolls arranged symmetrically. The groove structure allows the metal layer to be partially embedded in the fiber prepreg during rolling, reducing the probability of delamination.

[0030] In a preferred embodiment, the hot-melt section includes an infrared heating furnace 7, the heating temperature of which is 20°C higher than the melting point of the uppermost plate 3.

[0031] Here, the metal enters a superplastic state near its melting point, with accelerated atomic diffusion and grain boundary slip dominating deformation. When the temperature is 20°C above the melting point, the yield strength of the metal layer decreases by 30-50%, significantly reducing the pressure required for roll forming and effectively preventing tearing or debonding of the fiber layer due to high pressure. Simultaneously, the reduced metal flow stress fills the micron-level pores on the fiber layer surface, achieving a mechanical interlocking effect at the metal-fiber interface.

[0032] In a preferred embodiment, hot press lay-up rollers 8 are symmetrically arranged on both sides of the sheet 3 at the outlet end of the infrared heating furnace 7, and the hot press lay-up rollers 8 are arranged close to the infrared heating furnace 7.

[0033] In a preferred embodiment, the cooling and shaping section 2 includes an in-situ annealing component 9 and a cooling and shaping roller 10 placed behind the in-situ annealing component 9. The cooling and shaping roller 10 is in contact with the upper and lower end faces of the sheet material 3.

[0034] Here, the annealing temperature of the in-situ annealed part 9 is controlled to perform in-situ heat treatment on the welded layers, thereby reducing the cooling rate and increasing the crystallinity. A cooling and shaping roller 10 is set up to rapidly conduct heat, reducing the temperature of the metal layer from the plastic forming range to 100-150°C, preventing the recrystallization and coarsening of the metal layer, and maintaining a fine-grained structure. At the same time, the cooling and shaping roller constrains the elastic recovery of the material at high temperatures through high-pressure contact.

[0035] In a preferred embodiment, the roll gap pressure of the hot press layup roll 8 is 1~1.5MPa.

[0036] Here, the micro-mechanical interlocking effect between the metal layer and the fiber prepreg is enhanced under a pressure of 1~1.5MPa by the hot press layup roller 8, which can effectively fill the micropores on the metal surface, improve the interfacial shear strength, and simultaneously activate the flow characteristics of the thermoplastic film 12 within this pressure range, promoting its chemical bonding with the oxide layer of the metal plate 3.

[0037] In one preferred embodiment, the sheet materials 3 include, from top to bottom, thermoplastic woven carbon fiber prepreg 11, thermoplastic film 12, and metal sheet 13.

[0038] In a preferred embodiment, the laying controller 6, the forming roller 4, and the cooling and shaping roller 10 are controlled by the controller to adjust the up and down movement of the roller, and the controller is electrically connected to the laying controller 6, the forming roller 4, and the cooling and shaping roller 10.

[0039] The present invention has been further described above with reference to specific embodiments. However, it should be understood that the specific description herein should not be construed as limiting the substance and scope of the present invention. Various modifications made by those skilled in the art to the above embodiments after reading this specification are all within the scope of protection of the present invention.

Claims

1. A torch-assisted roll forming device for fiber-metal hybrid laminates, characterized in that, It includes a feeding section, a hot melting section, a molding section (1), a cooling and shaping section (2), and several layers of sheet metal (3). The sheet metal (3) is joined together at one end and then passes through the feeding section, the hot melting section, the molding section (1), and the cooling and shaping section (2) connected in sequence. The molding section (1) includes several forming rollers (4) that are equidistantly arranged on the upper and lower sides of the sheet metal (3). Each of the forming rollers (4) is provided with a hot torch (5) on the side of the hot melting section, and the hot torch (5) is placed on the upper end face after the sheet metal (3) is joined together.

2. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 1, characterized in that, The material feeding section includes a laying controller (6), and several of the plates (3) are respectively disposed on the left side of the laying controller (6), and the plates (3) converge and pass through the laying controller (6).

3. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 1, characterized in that, The forming roller (4) includes a grooved roller and a smooth roller. The grooved roller and the smooth roller are symmetrically arranged on both sides of the plate (3) and are in contact with the upper and lower end faces of the plate (3). The plate (3) forms a groove after passing through a number of grooved rollers and smooth rollers arranged vertically. The depth of the groove formed by each grooved roller and smooth roller is progressively increased.

4. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 1, characterized in that, The hot-melting section includes an infrared heating furnace (7), the heating temperature of which is 20°C higher than the melting point of the uppermost sheet material (3).

5. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 4, characterized in that, Hot press lay-up rollers (8) are symmetrically arranged on both sides of the sheet material (3) at the outlet end of the infrared heating furnace (7), and the hot press lay-up rollers (8) are arranged close to the infrared heating furnace (7).

6. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 2, characterized in that, The cooling and shaping section (2) includes an in-situ annealing part (9) and a cooling and shaping roller (10) placed behind the in-situ annealing part (9). The cooling and shaping roller (10) is in contact with the upper and lower end faces of the sheet material (3).

7. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 5, characterized in that, The roll gap pressure of the hot press lay-up roller (8) is 1~1.5MPa.

8. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 1, characterized in that, The sheet material (3) comprises, from top to bottom, thermoplastic woven carbon fiber prepreg (11), thermoplastic film (12), and metal sheet (13).

9. The torch-assisted roll forming equipment for fiber-metal hybrid laminates according to claim 6, characterized in that, The laying controller (6), forming roller (4) and cooling and shaping roller (10) are controlled by the controller to adjust the up and down movement of the roller, and the controller is electrically connected to the laying controller (6), forming roller (4) and cooling and shaping roller (10).

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