Ceramic Matrix Composite Bolt Preform Structural Integration Design
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Solution Overview
Problem
Current methods for designing ceramic matrix composite (CMC) bolts fail to accurately predict strength due to the lack of consideration for mesostructure influences, leading to structural failures such as screw fracture, thread tooth fracture, and bolt head fracture, which are not adequately addressed by macroscopic design approaches.
Innovation Solution
A structural integration design method for CMC bolt preforms that includes preform modeling, structure modeling, and deformation and failure calculation, allowing for the reflection of internal mesostructures and progressive damage analysis to improve strength prediction accuracy, incorporating mesoscopic and macroscopic parameters, and enabling parameterized design for wider application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a macroscopic design approach is used for CMC bolts, then the design process is simplified, but the prediction accuracy of bolt strength deteriorates due to lack of mesostructure consideration
Solution Approach 1:
The patent segments the CMC bolt model into multiple hierarchical levels: macroscopic bolt structure, mesoscopic preform structure, and microscopic fiber bundles. Each level is modeled separately with appropriate detail, allowing the design process to remain manageable while capturing critical mesostructural features that affect strength prediction accuracy.
Solution Approach 2:
The patent transitions from traditional single-scale macroscopic modeling to a multi-scale three-dimensional integrated model. By adding the mesoscopic dimension with explicit preform geometry and fiber bundle arrangements, the model captures out-of-plane stress states and failure modes that plane stress theories cannot predict, thereby improving strength prediction accuracy without overwhelming computational complexity.
2Ease of manufacture
If a simplified preform model with straight lines and rectangles is used, then the modeling process is easier, but the model cannot reflect actual mesostructures and solve practical engineering problems
Solution Approach 1:
The patent transforms the simplified geometric parameters (straight lines, rectangles) into realistic mesostructural parameters by importing actual preform geometry from CAD models. The model incorporates curved fiber paths, varying bundle densities, and complex preform shapes while maintaining computational tractability through parameterized definitions and automated meshing strategies.
Solution Approach 2:
The patent creates a digital copy of the actual preform geometry by importing CAD models directly into the finite element model. This copying approach preserves the exact mesostructural features of the physical preform, including fiber bundle arrangements and preform shape, enabling accurate prediction of practical engineering problems without manual simplification.
3Ease of operation
If CMC bolt design only considers macroscopic parameters, then the design method is simpler to implement, but different mesostructures of the same material lead to different calculation results reducing prediction accuracy
Solution Approach 1:
The patent segments the design parameters into macroscopic bolt geometry parameters and mesoscopic preform parameters, allowing each to be optimized independently. The macroscopic design remains simple to implement, while the mesoscopic parameters are automatically generated from preform CAD models, combining ease of operation with accurate prediction of mesostructure-influenced behavior.
Solution Approach 2:
The patent creates a universal modeling framework that can handle both simple and complex preform geometries through a unified approach. The same modeling procedure works for various preform types by simply changing the input CAD model, making the method easy to implement across different applications while accurately capturing mesostructural effects on strength prediction.
Data Source
AI summary
A structural integration design method for a ceramic matrix composite bolt preform is provided, which includes: preform modeling; structure modeling; deformation and failure calculation. The method builds different small composites inside the bolt according to actual mesostructures of the ceramic matrix composites, which can realize structurally macroscopic failures caused by mesoscopic failures inside the small composites. The screw threads that are built by the method can reflect a failure form of thread teeth, and the influence of complex stress conditions of the screw threads on the failure form of the screw fracture is also considered, which improves the prediction accuracy of the strength of the ceramic matrix composite bolt. The method builds a structure integrated model, which has a certain structure, for a ceramic matrix composite preform according to the actual size and shape of the structure. The model can have high accuracy, accurately reflect various components of the material, and give macroscopic and mesoscopic structural parameters, so as to facilitate the machining of preparation personnel.