Z-direction yarn implantation method for composite-material additive manufacturing

Abstract

Disclosed in the present application is a Z-direction yarn implantation method for composite-material additive manufacturing, which can introduce a fiber in a Z direction of a composite-material component to improve the bearing performance of the composite-material component. The method comprises: dividing a three-dimensional model of a composite-material component into a printing area and a yarn implantation area extending in a Z direction; performing printing on the basis of the cross-section contour of the printing area in an X-Y plane, so as to obtain a printing area bottom; arranging an implantation head in the printing area bottom, wherein the implantation head is arranged corresponding to the yarn implantation area, and carries an introduced fiber; performing layer-by-layer printing on an upper surface of the printing area bottom on the basis of the cross-section contour of the printing area in the X-Y plane; driving the implantation head to move in the Z direction so as to drive the introduced fiber to the position of a printed layer, wherein the moving distance of the implantation head is the layer thickness of a layer to which the printing area belongs; repeating the printing and implantation steps, so as to obtain the composite-material component; and driving the implantation head to move outside of the composite-material component, removing the implantation head, and leaving the introduced fiber inside the composite-material component.

Description

Z-direction yarn planting method for additive manufacturing of composite materials

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on December 22, 2023, with application number 202311787975.9 and invention name “Z-direction yarn planting method for additive manufacturing of composite materials”, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the technical field of composite materials and additive manufacturing, and in particular to a Z-direction yarn planting method for additive manufacturing of composite materials. Background Art

[0004] Fiber-based additive manufacturing (CFAM) is a process that combines fibers with resins and prints them layer by layer with appropriate process parameters to form composite components. It can achieve high-performance manufacturing of composite materials with integrated structure and function, and is widely used in the formation of complex structural composite components.

[0005] However, the layer-by-layer printing method based on fiber additive manufacturing results in no fiber load-bearing in the Z direction inside the composite components obtained by additive manufacturing, making it difficult to meet the load-bearing performance requirements of composite components.

[0006] Summary of the Invention

[0007] In view of this, the present application provides a Z-direction yarn planting method for additive manufacturing of composite materials to solve the problem of poor bearing performance of composite components obtained by additive manufacturing.

[0008] In a first aspect, the present application provides a Z-direction yarn planting method for additive manufacturing of composite materials, for obtaining composite material components. Specifically, the Z-direction yarn planting method for additive manufacturing of composite materials includes the following steps: zoning, i.e., dividing a three-dimensional model of the composite material component into a printing area and a yarn planting area, wherein the yarn planting area is arranged along the Z-direction extension of the composite material component; pre-printing, i.e., printing a certain thickness according to the cross-sectional profile information of the printing area in the XY plane to obtain the bottom of the printing area; implantation preparation, i.e., arranging an implantation head in the bottom of the printing area, wherein the implantation head is arranged corresponding to the yarn planting area and the implantation head carries an introduced fiber; printing, i.e., printing layer by layer on the upper surface of the bottom layer of the printing area according to the cross-sectional profile information of the printing area in the XY plane; implantation, i.e., driving the implantation head to move along the Z direction and driving the introduced fiber to the position of the printed layer, wherein the moving distance of the implantation head is the layer thickness of the layer to which the printing area belongs; repeating the printing step and the implantation step to obtain the composite material component; removal, i.e., driving the implantation head to move outside the composite material component, removing the implantation head, and leaving the introduced fiber inside the composite material component.

[0009] Beneficial effects: This solution improves the Z-direction bearing capacity of composite components by reserving a yarn planting area and implanting Z-direction introduced fibers during the form-fitting printing process in the printing area through an implantation head, thereby improving the interlayer performance of composite components and enhancing the bearing performance of composite components.

[0010] In an optional embodiment, the yarn planting area has a plurality of sub-yarn planting areas, and the plurality of sub-yarn planting areas are arranged at intervals in the printing area.

[0011] Beneficial effect: The Z-yarn planting areas spaced apart in the printing area facilitate increasing the implantation density of the fibers introduced in the Z direction, thereby further improving the load-bearing capacity and comprehensive performance of the composite material components.

[0012] In an optional embodiment, the plurality of sub-yarn planting areas are distributed in an array.

[0013] Beneficial effects: The sub-planted yarn area is distributed in an array, so that the implanted Z-direction introduced fibers are also distributed in an array within the composite material component. The distribution of the introduced fibers is uniform, which facilitates enhancing the uniformity of the interlayer performance of the composite material and further improving the load-bearing performance and comprehensive performance of the composite material component.

[0014] In an optional embodiment, the cross-sectional shape of the sub-yarn planting area in the XY plane can be configured as a circle, a polygon, or an irregular shape.

[0015] Beneficial effects: Based on the limitations of additive manufacturing technology and composite materials, the cross-sectional shape of the sub-yarn area of ​​this scheme can be constructed in a variety of ways, which is convenient for adjustment according to actual conditions, so as to smoothly carry out the printing of the bottom of the printing area and the printing layers printed layer by layer, with high convenience and freedom.

[0016] In an optional embodiment, during the implantation step and the removal step, the composite material component is printed horizontally. Furthermore, during the implantation step and the removal step, a magnetic device is placed on one side of the implant head, and the implant head is driven to move by the magnetic device. Alternatively, the pneumatic part of the pneumatic device is placed at the tail of the implant head, and the limiting part of the pneumatic device is placed at the head of the implant head, the implant head is driven to move by the pneumatic part, and the moving position of the implant head is limited by the limiting part. Beneficial effects: easy to implement and highly reliable.

[0017] In an optional embodiment, the introduced fibers are continuous fibers or continuous fiber composite filaments. Alternatively, the introduced fibers are made of one or more of continuous carbon fibers, continuous aramid fibers, continuous glass fibers, continuous quartz fibers, continuous silicon carbide fibers, continuous ultra-high molecular weight polyethylene fibers, continuous carbon fiber reinforced polyetheretherketone composite filaments, continuous aramid fiber reinforced nylon composite filaments, and continuous glass fiber reinforced polyetheretherketone composite filaments.

[0018] Beneficial effect: It is easy to obtain composite components with higher performance and quality.

[0019] In an optional embodiment, after the removal step, the method further includes a step of heat curing, i.e., placing the composite component into a mold, and then placing it in a heatable device, heating it to a melting temperature to allow the resin in the printed area to bond with the fibers or resin in the yarn-planted area, and then cooling it to form a monolithic component. Alternatively, before the heat curing step, the method further includes a step of fixing, i.e., printing on the top and bottom surfaces of the composite component to form a fixing layer; the fixing layer covers the cross-sectional profile of the yarn-planted area in the XY plane.

[0020] Beneficial effects: In this solution, through the heating, curing and fixing steps, the introduced fibers and composite material components are constructed into an integral structure with high reliability.

[0021] In an optional embodiment, in the fixing step, two ends of the introduced fiber extend out of the top and bottom of the composite material component by predetermined lengths, respectively.

[0022] Beneficial effect: With this arrangement, when the fixing layers are printed on the top and bottom of the composite component, both ends of the introduced fiber can be bonded to the fixing layers, thereby improving the stability of the introduced fiber.

[0023] In an optional embodiment, after the partitioning step and before the pre-printing step, the step is also included: obtaining a printing platform, that is, opening an implantation hole on the printing platform according to the cross-sectional profile information of the yarn planting area in the XY plane; the implantation hole has the same cross-sectional structure as the yarn planting area.

[0024] Beneficial Effects: The printing platform provides a printing surface for additive manufacturing of composite components, and the implantation holes of the printing platform facilitate the arrangement of implantation heads. Specifically, each implantation head and the introduced fiber it carries are inserted into one of the implantation holes.

[0025] In an optional embodiment, before the pre-printing step, a process parameter determination step is also included, and the process parameter determination step includes: layering the printing area to obtain cross-sectional profile information of each layer in the printing area and the printing thickness of each layer; wherein the cross-sectional profile information is the cross-sectional profile of the printing area in the XY plane; according to the cross-sectional profile information and the target performance parameters of the composite material component, the printing path, printing spacing, printing speed and printing temperature are obtained.

[0026] Beneficial effects: Determining process parameters facilitates accurate acquisition of composite components with predetermined dimensions and mechanical properties, with high reliability and a high degree of automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the specific implementation methods of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the specific implementation methods or the description of the prior art. Obviously, the drawings described below are some implementation methods of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0028] FIG1 is a flow chart of a Z-direction yarn planting method for additive manufacturing of composite materials according to an embodiment of the present application;

[0029] FIG2 is a schematic structural diagram of a three-dimensional model of a composite material partition using a Z-direction yarn planting method for additive manufacturing of a composite material according to an embodiment of the present application;

[0030] FIG3 is a schematic diagram of a state during implementation of a Z-direction yarn planting method for additive manufacturing of a composite material according to an embodiment of the present application;

[0031] FIG4 is a schematic diagram of a state during implementation of a Z-direction yarn planting method for additive manufacturing of composite materials according to another embodiment of the present application;

[0032] FIG5 is a schematic diagram of another state during the implementation of a Z-direction yarn planting method for additive manufacturing of a composite material according to an embodiment of the present application;

[0033] FIG6 is a schematic diagram of a printing platform structure according to an embodiment of the present application.

[0034] Explanation of the accompanying symbols: 1. Printing area; 2. Yarn planting area; 21. Sub-yarn planting area; 3. Bottom of the printing area; 31. Through channel; 4. Implantation head; 5. Introducing fiber; 6. Magnetic suction device; 7. Printing platform; 71. Implantation hole; 8. Pneumatic device; 81. Pneumatic part; 82. Limiting part. DETAILED DESCRIPTION

[0035] To make the purpose, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without making creative efforts shall fall within the scope of protection of this application.

[0036] Fiber-based additive manufacturing (CFAM) is a process that combines fibers with resins and prints them layer by layer with appropriate process parameters to form composite components. It can achieve high-performance manufacturing of composite materials with integrated structure and function, and is widely used in the formation of complex structural composite components.

[0037] However, the layer-by-layer printing method based on fiber additive manufacturing results in no fiber load-bearing in the Z direction inside the composite components obtained by additive manufacturing, making it difficult to meet the load-bearing performance requirements of composite components.

[0038] Based on this, the present application provides a Z-direction yarn planting method for additive manufacturing of composite materials to solve the problem of poor bearing performance of composite components obtained by additive manufacturing.

[0039] The following describes an embodiment of the present application in conjunction with Figures 1 to 5.

[0040] According to an embodiment of the present application, on the one hand, a Z-direction yarn planting method for composite material additive manufacturing is provided, for obtaining a composite material component. Specifically, the method includes the following steps:

[0041] S10: partitioning, that is, dividing the three-dimensional model of the composite component into a printing area 1 and a yarn planting area 2; wherein the yarn planting area 2 is arranged to extend along the Z direction of the composite component;

[0042] S20: Pre-printing, i.e., printing a certain thickness according to the cross-sectional profile information of the printing area 1 in the XY plane to obtain the bottom 3 of the printing area;

[0043] S30: implantation preparation, i.e., arranging an implantation head 4 in the bottom 3 of the printing area, wherein the implantation head 4 is arranged corresponding to the yarn implantation area 2, and the implantation head 4 carries the introduced fiber 5;

[0044] S40: Printing, i.e., printing layer by layer on the upper surface of the bottom 3 of the printing area according to the cross-sectional profile information of the printing area 1 in the XY plane;

[0045] S50: implantation, i.e. driving the implantation head 4 to move along the Z direction and bring the introduced fiber 5 to the position of the printed layer; wherein the movement distance of the implantation head 4 is the thickness of the layer to which it belongs;

[0046] S60: Repeat the printing step and the implantation step to obtain a composite material component;

[0047] S70: Taking out, that is, driving the implantation head 4 to move outside the composite material component, taking out the implantation head 4, and leaving the introduced fiber 5 inside the composite material component.

[0048] In this embodiment, by reserving a yarn planting area 2 and implanting Z-direction introduced fibers 5 during the form-fitting printing of the printing area 1 through the implantation head 4, the Z-direction bearing capacity of the composite material component is improved, thereby improving the interlayer performance of the composite material component and enhancing the bearing performance of the composite material component.

[0049] Taking FIG. 2 as an example, the Z direction refers to the height direction of the three-dimensional model of the composite material component, and the XY plane refers to a plane perpendicular to the Z direction.

[0050] It can be understood that the above-mentioned implementation steps of the present application do not have to be performed in sequence. For example, the above-mentioned implantation preparation step can also be implemented before the pre-printing step, that is, the implantation head 4 is first arranged according to the position of the yarn planting area 2, and then pre-printing is performed.

[0051] Furthermore, the composite material in the present application includes a matrix material and a reinforcement material, wherein the matrix material is a resin, and the reinforcement material can be one or more of short fibers, long fibers or continuous fibers.

[0052] For example, the reinforcement material of the composite material may be one or more of carbon fiber, aramid fiber, glass fiber, quartz fiber, silicon carbide fiber, and ultra-high molecular weight polyethylene fiber.

[0053] It should be noted that in the partitioning step, the three-dimensional model of the composite component is divided into a printing area 1 and a yarn planting area 2, wherein the printing area 1 is formed by additive manufacturing printing, and the yarn planting area 2 does not participate in printing. The yarn planting area 2 is used to arrange the introduced fibers 5 in the Z direction.

[0054] In the pre-printing step, the bottom 3 of the printing area is printed with a certain thickness to provide a Z-direction guide for the implant head 4. Exemplarily, in the pre-printing step, the printing thickness of the bottom 3 of the printing area can be 1-10 mm.

[0055] In the printing step, printing is performed layer by layer on the upper surface of the bottom layer 3 of the printing area, and each time the printing step is performed, a printing layer is obtained above the bottom layer of the printing area.

[0056] In the pre-printing and printing steps, the bottom 3 of the printing area and the printing layer are printed according to the cross-sectional profile information of the printing area 1 in the XY plane, while the position corresponding to the cross-sectional profile of the yarn planting area in the XY plane is not printed. The bottom 3 of the printing area and the printing layer both reserve positions corresponding to the yarn planting area 2, so that the implantation head 4 can implant the introduced fiber 5 at the position corresponding to the yarn planting area 2.

[0057] It should be noted that, as shown in Figures 3 and 4, the bottom portion 3 of the printing area may include multiple unit layers stacked along the Z-direction, where a unit layer refers to a single layer structure obtained during each printing. It is understood that the specific structure of the unit layers depends on the 3D model of the composite component. Therefore, the specific structure of the bottom portion 3 of the printing area also depends on the 3D model of the composite component. The structures of the multiple unit layers in the bottom portion 3 of the printing area may be the same or different.

[0058] For example, during the implantation preparation step, the lead-in fiber 5 can be connected to the tail of the implantation head 4. When the implantation head 4 moves along the Z direction, it can drive the lead-in fiber 5 at its tail into the bottom 3 of the printing area and the printed layer. For example, the lead-in fiber 5 can be inserted into the tail of the implantation head 4 or tied to the tail of the implantation head 4.

[0059] Specifically, the introduced fibers 5 may be continuous fibers or continuous fiber composite filaments. For example, the introduced fibers 5 may be one or more of carbon fibers, aramid fibers, glass fibers, quartz fibers, silicon carbide fibers, continuous carbon fiber reinforced polyetheretherketone composite filaments, continuous aramid fiber reinforced nylon composite filaments, and continuous glass fiber reinforced polyetheretherketone composite filaments. When the introduced fibers 5 are continuous fiber composite filaments, the reinforcement material therein is preferably continuous fiber.

[0060] For example, the other end of the introduced fiber 5 facing away from the implantation head 4 can be wound around a pay-off wheel.

[0061] During the implantation step, the implantation head 4 drives the introduced fiber 5 to the position of the printed layer, which specifically refers to the printed layer obtained after the current printing step is implemented. The distance moved by the implantation head is the thickness of the layer to which the printing area belongs, which specifically refers to the thickness of the printed layer obtained each time the printing step is implemented.

[0062] In the printing step, the printed layer may include one unit layer or multiple unit layers stacked along the Z direction. Optionally, the printed layer includes one unit layer, and accordingly, in the implantation step, the implantation head 4 drives the introduced fiber 5 to move along the Z direction by the thickness of one unit layer.

[0063] It is understandable that during the implantation process, the height of the top of the implantation head 4 is always lower than the height of the current printing layer to avoid interference with the printing equipment.

[0064] In the process of repeating the printing step and the implanting step, the number of repetitions depends on the size of the composite material component.

[0065] In the removal step, the implant head 4 moves outside the composite component and drives part of the structure of the introduced fiber 5 outside the composite component. At this time, the introduced fiber 5 can be cut at a position close to the composite component by a cutting mechanism.

[0066] In some embodiments, the yarn planting area 2 has multiple sub-yarn planting areas 21, and the multiple sub-yarn planting areas 21 are arranged at intervals in the printing area 1. Providing the Z-direction yarn planting areas 2 arranged at intervals in the printing area 1 facilitates increasing the implantation density of the Z-direction introduced fibers 5, further improving the load-bearing performance and overall performance of the composite material component.

[0067] Furthermore, multiple sub-yarn areas 21 can be distributed in an array, so that the implanted Z-direction introduced fibers 5 are also distributed in an array within the composite material component. The distribution of the introduced fibers 5 is uniform, which facilitates enhancing the uniformity of the interlayer performance of the composite material and further improving the load-bearing performance and comprehensive performance of the composite material component.

[0068] Specifically, the arrangement and number of the sub-yarn planting areas 21 depend on the target performance parameters of the composite material component.

[0069] For example, as shown in Figure 2, the sub-yarn planting area 21 is arranged in an array of five rows and five columns. The printed area bottom 3 and printed layer obtained in the pre-printing and printing steps are both constructed as a grid structure, with five rows and five columns of through-holes along the Z-direction. Accordingly, multiple implantation heads 4 are provided, each positioned within one of the through-holes, and each carries an introduction fiber 5 at its tail end.

[0070] Furthermore, the cross-sectional shape of the sub-growth yarn area 21 in the XY plane can be configured as a circle, a polygon, or an irregular shape. Based on the limitations of the additive manufacturing process and the composite material, in this embodiment, the cross-sectional shape of the sub-growth yarn area 21 can be configured in a variety of ways, which can be easily adjusted according to actual conditions to smoothly print and form the bottom 3 of the printing area and the printing layer, with high convenience and freedom.

[0071] The polygon can be a regular polygon or an irregular polygon. The present application does not specifically limit the cross-sectional shape of the sub-yarn planting area 21, as long as additive manufacturing can be achieved. Optionally, the cross-sectional shape of the sub-yarn planting area 21 in the XY plane can be configured as a circle, a square, a rectangle, or a hexagon. Taking Figure 2 as an example, the sub-yarn planting area 21 is configured as a square.

[0072] Furthermore, the composite material component includes a printing area bottom 3 and multiple printing layers, which are stacked along the Z direction. The printing area bottom 3 and the multiple printing layers together form multiple through-channels 31, each through-channel 31 corresponding to a sub-yarn planting area 21, and the lead-in fiber 5 is arranged in the through-channel 31. In this arrangement, the lead-in fiber 5 can be arranged through the composite material component along the Z direction, and the reliability of the Z-direction load-bearing is high. In addition, the arrangement of the through-channel 31 facilitates the implantation head 4 to implant the lead-in fiber 5.

[0073] In some embodiments, during the implantation step and the removal step, the composite material component is printed in a horizontal manner. Specifically, horizontal printing refers to printing on a vertical plane, with the implantation head 4 being placed horizontally.

[0074] Furthermore, during the implantation and removal steps, a magnetic device 6 is placed on one side of the implant head 4, magnetically driving the implant head 4 to move. Alternatively, a pneumatic member 81 of a pneumatic device 8 is placed at the rear of the implant head 4, and a position-limiting member 82 of the pneumatic device 8 is placed at the head of the implant head 4. The pneumatic member 81 drives the implant head 4 to move, while the position-limiting member 82 limits the movement of the implant head 4. This arrangement is not only easy to implement but also highly reliable.

[0075] Referring to Figure 3, the magnetic attraction device 6 may include a flat structure, which is located at the bottom 3 of the printing area or the printing side of the printing layer, as shown on the right side of Figure 3. There is a magnetic attraction between the flat structure and the implant head 4. Starting the magnetic attraction device 6 causes the flat structure to move along the Z direction, thereby driving the implant head 4 to move along the Z direction.

[0076] In actual application, when implementing the pre-printing or printing steps, the magnetic device 6 drives the flat structure away from the printing area. After the printing of the bottom 3 of the printing area or a printing layer is completed, the flat structure approaches the current printing layer and drives each implant head 4 to move to the specified position through magnetic attraction.

[0077] For example, the flat plate structure and the implant head 4 may be ferromagnetic or electromagnetic.

[0078] For example, during the implantation step and the removal step, a pneumatic or buoyancy device may be used to drive the implantation head 4 to move.

[0079] Referring to Figure 4 , the pneumatic device 8 comprises a pneumatic element 81 and a stopper 82. The pneumatic element 81 is located at the rear of the implant head 4 and is capable of moving the implant head using air or high-pressure gas. The stopper 82, located at the head of the implant head 4, limits the movement of the implant head 4 and prevents it from protruding from the surface of the currently printed layer. Accordingly, the stopper 82 is provided with multiple holes. Air or compressed gas is blown in by the pneumatic element 81 and escapes through the holes in the stopper 82. The cross-sectional dimensions of these holes are smaller than those of the implant head 4.

[0080] In actual application, when implementing the pre-printing or printing steps, the pneumatic device 8 drives the limiter 82 away from the printing area. After the printing of the bottom 3 of the printing area or a printing layer is completed, the limiter 82 is against one side of the current printing layer, and the pneumatic device 8 drives the pneumatic part 81 to blow air toward the implantation head 4, driving each implantation head 4 to move to the position where the limiter 82 is located, and stops moving under the resistance of the limiter 82.

[0081] For example, the Z-direction yarn planting method for additive manufacturing of composite materials of the present application can adopt a horizontal printing method.

[0082] In some embodiments, after the removing step, the method further comprises the steps of:

[0083] S90: Heating and curing, that is, placing the composite material component into a mold, and then placing it into a heating device, heating it to the melting temperature to combine the resin in the printing area 1 with the fiber or resin in the yarn planting area 2, and forming an integral component after the temperature is lowered.

[0084] In other embodiments, before the heating and curing step, the method further comprises the following steps:

[0085] S80: Fixing, i.e. printing on the top and bottom surfaces of the composite material component to obtain a fixing layer; the fixing layer covers the cross-sectional profile of the yarn planting area 2 in the XY plane.

[0086] In this embodiment, by covering the top and bottom surfaces of the composite component with a fixing layer, the introduced fiber 5 located in the yarn planting area 2 can be fixed in the composite component, so that the introduced fiber 5 and the composite component are constructed into an integral structure.

[0087] It is understandable that when this embodiment is implemented, in the partitioning step, before dividing the printing area 1 and the yarn planting area 2, a portion of the fixed layer can be pre-divided to ensure the accuracy of the size of the composite material component.

[0088] Furthermore, during the fixing step, the ends of the introduced fiber 5 extend beyond the top and bottom of the composite component by a predetermined length. This allows the ends of the introduced fiber 5 to be bonded to the fixing layers when the fixing layers are printed on the top and bottom of the composite component, improving the stability of the introduced fiber 5.

[0089] It is understood that there are two fixed layers, one at the top and one at the bottom of the composite component, and that the two fixed layers can have the same or different configurations, depending on the shape and configuration of the composite component. Each fixed layer can include a single unit layer or multiple unit layers stacked along the Z-direction. Optionally, the fixed layer includes a single unit layer.

[0090] Specifically, the fixing step includes the following steps:

[0091] S81: Reserving a certain length of the introduction fiber 5 on the top of the composite component, and printing on the top of the composite component to obtain a first fixed layer; one end of the introduction fiber 5 is fixed in the first fixed layer;

[0092] S82: A certain length of introduced fiber 5 is reserved at the bottom of the composite component, and the composite component is turned over, and printing is performed on the bottom surface of the composite component to obtain a second fixed layer; the other end of the introduced fiber 5 is fixed in the second fixed layer.

[0093] Furthermore, after the partitioning step and before the pre-printing step, the method further includes the following steps:

[0094] A printing platform 7 (see FIG5 ) is obtained, that is, an implantation hole 71 is opened on the printing platform 7 according to the cross-sectional profile information of the yarn implantation area 2 in the XY plane; wherein the implantation hole 71 has the same cross-sectional structure as the yarn implantation area 2 .

[0095] First, the printing platform 7 provides a printing surface for additive manufacturing of composite components. Second, the implantation holes 71 of the printing platform 7 facilitate the arrangement of the implantation heads 4. Specifically, each implantation head 4 and the introduced fiber 5 it carries are inserted into one of the implantation holes 71.

[0096] Furthermore, before the pre-printing step, a process parameter determination step is also included. The process parameter determination step specifically includes:

[0097] The printing area 1 is layered to obtain cross-sectional profile information and the printing thickness of each layer of the printing area 1; wherein the cross-sectional profile information is the cross-sectional profile of the printing area 1 in the XY plane; wherein the printing path of each unit layer of the printing area 1 can be obtained based on the cross-sectional profile of each layer in the XY plane and the target mechanical properties of the composite material component;

[0098] According to the cross-sectional profile information and the target performance parameters of the composite component, the printing path, printing spacing, printing speed and printing temperature are obtained.

[0099] In this embodiment, determining the process parameters facilitates accurate acquisition of composite material components with predetermined dimensions and mechanical properties, with high reliability and a high degree of automation.

[0100] Taking the composite material of printing area 1 as aramid reinforced nylon 12 and the material of introduced fiber 5 in yarn planting area 2 as continuous carbon fiber as an example, the printing layer thickness is 0.6mm, the printing spacing is 1.1mm-1.5mm, the printing speed is 2mm / s-10mm / s, the temperature of printing platform 7 is 60℃, and the printing temperature is 280℃.

[0101] It can be understood that, in this embodiment, the printing area 1 is layered, and the single-layer structure obtained by printing according to the cross-sectional profile information and printing thickness of each layer is the above-mentioned unit layer.

[0102] Furthermore, before the partitioning step, the method may further include the step of constructing a three-dimensional model of the composite component, which may be produced using three-dimensional software. The constructed three-dimensional composite model can accurately describe the dimensional information of the composite component and reflect its mechanical performance requirements.

[0103] Specifically, taking the composite material of the printing area 1 as carbon fiber reinforced polyetheretherketone and the material of the introduced fiber 5 of the yarn planting area 2 as continuous carbon fiber as an example, the specific steps are as follows:

[0104] Analyze the structure of composite components and construct their three-dimensional models;

[0105] The three-dimensional model is divided into a printing area 1 and a yarn planting area 2; wherein the yarn planting area 2 has a plurality of sub-yarn planting areas 21, and accordingly, the printing area 1 is a porous structure;

[0106] Use slicing software to layer the printing area 1, obtain the contour information of each layer, and plan the path based on the target mechanical properties of the composite component;

[0107] Determine the process parameters: print layer thickness of 0.4mm, print spacing of 1.1mm-1.5mm, print speed of 2mm / s-10mm / s, print platform temperature of 100℃, and print temperature of 380℃;

[0108] Connect the implantation head 4 and the introduced fiber 5 and arrange them in the yarn planting area 2, start the magnetic device, and adjust the pay-off wheel so that the implantation head 4 is lower than the height of the printing platform 7;

[0109] The printer parameters are set according to the above process parameters, and the printing of the first unit layer is started. After the printing of the first unit layer is completed, the pay-off wheel is adjusted to raise the implantation head 4 by 0.4 mm. The implantation head 4 drives the introduced fiber 5 to move upward by 0.4 mm, and then the second unit layer is printed until the printing of the bottom 3 of the printing area is completed.

[0110] The next unit layer is printed on top of the bottom 3 of the printing area to obtain a printed layer. After the printed layer is printed, the pay-off wheel is adjusted to raise the implantation head 4 by 0.4 mm. The implantation head 4 drives the introduced fiber 5 to move upward by 0.4 mm. This step is repeated until all layers are printed.

[0111] The pay-off wheel is adjusted to allow the implanting head 4 to pass through the printing area 1 to complete the penetration of the Z-direction fiber, and the implanting head 4 is removed.

[0112] The Z-direction yarn planting method for additive manufacturing of composite materials provided in this application obtains a composite material component through additive manufacturing of fiber-reinforced composite materials, and implants Z-direction introduced fibers 5 into the composite material component, which can solve the problem of no Z-direction fiber load-bearing in additive manufacturing of fiber-reinforced composite materials and improve the mechanical properties of the composite material component.

[0113] Although the embodiments of the present application have been described with reference to the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present application, and such modifications and variations shall fall within the scope defined by the appended claims.

Claims

1. A Z-direction yarn planting method for additive manufacturing of composite materials, used to obtain composite material components, characterized in that, Including the following steps: Partitioning: Divide the three-dimensional model of the composite material component into a printing area (1) and a fiber implantation area (2); the fiber implantation area (2) is arranged to extend along the Z direction of the composite material component; Pre-printing: According to the cross-sectional profile information of the printing area (1) in the X-Y plane, print a certain thickness to obtain the bottom of the printing area (3); Implantation preparation: Arrange an implantation head (4) in the bottom of the printing area (3); the implantation head (4) is arranged corresponding to the fiber implantation area (2), and the implantation head (4) carries an introducing fiber (5); Printing: According to the cross-sectional profile information of the printing area (1) in the X-Y plane, perform layer-by-layer printing on the upper surface of the bottom of the printing area (3); Implantation: Drive the implantation head (4) to move along the Z direction, and drive the introducing fiber (5) to the position of the printed layer; the moving distance of the implantation head (4) is the layer thickness of the layer to which the printing area (1) belongs; Repeat the printing step and the implantation step to obtain the composite material component; Removal: Drive the implantation head (4) to move outside the composite material component, remove the implantation head (4), and leave the introducing fiber (5) inside the composite material component.

2. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 1, characterized in that The fiber implantation area (2) has a plurality of sub-fiber implantation areas (21), and the plurality of sub-fiber implantation areas (21) are arranged at intervals in the printing area (1).

3. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 2, characterized in that, The plurality of sub-fiber implantation areas (21) are arranged in an array.

4. The method for Z-direction yarn planting in additive manufacturing of composite materials according to claim 2 or 3, characterized in that, The cross-sectional shape of the sub-fiber implantation area (21) in the X-Y plane can be configured as a circle, a polygon, or an irregular shape.

5. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 1, characterized in that, The composite material component is printed horizontally; In the implantation step and the removal step, place a magnetic attraction device (6) on one side of the implantation head (4), and magnetically attract and drive the implantation head (4) to move through the magnetic attraction device (6); Alternatively, place a pneumatic component (81) of a pneumatic device (8) at the tail of the implantation head (4), and place a limiting component (82) of the pneumatic device (8) at the head of the implantation head (4), drive the implantation head (4) to move through the pneumatic component (81), and limit the moving position of the implantation head (4) through the limiting component (82).

6. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 1, characterized in that, The introducing fiber (5) is one or more of continuous fibers or continuous fiber composite filaments; Optionally, the material of the introducing fiber (5) is one or more of continuous carbon fiber, continuous aramid fiber, continuous glass fiber, continuous quartz fiber, continuous silicon carbide fiber, continuous ultra-high molecular weight polyethylene fiber, continuous carbon fiber reinforced polyetheretherketone composite filament, continuous aramid fiber reinforced nylon composite filament, and continuous glass fiber reinforced polyetheretherketone composite filament.

7. The Z-direction yarn planting method for composite material additive manufacturing according to claim 6, characterized in that, After the removal step, it further includes the step of: Heating and curing: Place the composite material component into a mold, and then place it into a device that can be heated and raised in temperature, raise the temperature to the melting temperature to bond the resin in the printing area (1) with the fiber or resin in the fiber implantation area (2), and form an integral component after the temperature decreases; Or, before the heating and curing step, it further includes the step of: Fixing: Print on the top surface and the bottom surface of the composite material member to obtain a fixing layer; the fixing layer covers the cross-sectional contour of the yarn implantation area (2) in the X-Y plane.

8. The Z-direction yarn planting method for composite material additive manufacturing according to claim 7, characterized in that, In the fixing step, both ends of the introduced fiber (5) extend out of the top and bottom of the composite material member by a predetermined length.

9. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 1, characterized in that, After the partitioning step and before the pre-printing step, the method further includes the steps of: Obtaining a printing platform (7): According to the cross-sectional contour information of the yarn implantation area (2) in the X-Y plane, implanting holes (71) are formed in the printing platform (7); the implanting holes (71) have the same cross-sectional structure as the cross-section of the yarn implantation area (2).

10. The Z-direction yarn planting method for additive manufacturing of composite materials according to claim 1, characterized in that, Before the pre-printing step, the method further includes a step of determining process parameters, and the step of determining process parameters includes: Layering the printing area (1) to obtain the cross-sectional contour information of each layer of the printing area (1) and the printing thickness of each layer; wherein, the cross-sectional contour information is the cross-section of the printing area (1) in the X-Y plane cross-sectional contour; According to the cross-sectional contour information and the target performance parameters of the composite material member, obtain the printing path, printing spacing, printing speed and printing temperature.

Images