复合材料缠绕铺放成型工艺参数对制品性能耦合作用机理研究

This subject puts the process control as the carrier in tape warping and laying process of composites, takes the effect of process parameters to the molded product performance as the research object. Aimed at the challenge of the mechanism of the effect of process parameters on product performance, the prediction of product performance, control, macro-evaluation, etc, the process is tested. Through the test of product performance, test analysis, and simulation, the influence rule of process parameters on molding process and product performance is grasped. Based on the sensitivity of the controllable process parameters on product performance, a molding process control and product performance evaluation system is established. The control method of product performance stability domain based on process parameters sensitivity is proposed, the mechanism model on the coupling of process parameters to product performance is established. The coupled mechanism of process parameters to the process and product performance is revealed. we optimize the process parameters of the multi-target and multi-parameter coupling based on grey correlation analysis. Expect to get the basic theory and data in the selection and control of process parameters which is based on product performance requirements. This research can promote to cognize the mechanism of the influence of process parameters on molding process and product performance, enrich the moldings performance control study basic theory and promote the advances of molding technology. This project has theoretical significance and value of engineering applications to the development of new concepts aerospace engines, large aircraft composite structural test pieces in major science and technology projects in the national security.

本课题以复合材料缠绕铺放成型工艺过程控制为载体，以工艺参数对成型制品性能影响为研究对象，针对成型工艺过程中存在工艺参数对制品性能影响机理、性能预测、控制、宏观评价等难题，进行工艺试验，通过制品性能试验、测试分析、仿真计算等，掌握工艺参数对成型工艺过程及制品性能的影响规律。基于可控工艺参数对制品性能影响的敏感度，建立成型工艺控制方法和制品性能评价体系；提出基于工艺参数敏感度的制品性能稳定域控制方法，建立工艺参数对制品性能耦合作用机理模型，揭示工艺参数对工艺过程及制品性能影响的耦合作用机理；通过对多目标多参数耦合作用的工艺参数进行优化，获得依据制品性能要求选择和控制工艺参数的基础理论和数据。课题研究可促进认知工艺参数对成型工艺过程及制品性能影响机理，丰富成型制品性能控制研究的基础理论，对国家安全重大科技工程中新概念航空航天发动机、大型飞机复合材料结构试验件的研制具有理论指导意义和应用价值。

为采用预浸料缠绕及铺放工艺制备高质量的制品，必须合理选择工艺参数，严控制造工艺参数的精度。基于此，本项目针对预浸料成型过程中工艺参数对制品层间结合强度、孔隙率、残余应力及拉伸强度的影响机理及参数控制等问题进行研究，建立了预浸带成型制品层间剪切强度、孔隙率及残余应力机理建模。对于制品残余应力，提出基于理论模型逆向求解设计缠绕张力的方法；对应孔隙率及剪切强度，提出了基于敏感度分析的稳定域划分方法，得到了面向层间剪切强度和孔隙率的工艺参数稳定域。仿真结果表明了温度、压力、缠绕张力和速度分别对缠绕制品性能表征参数的耦合影响机理，在此基础上对工艺参数进行优化并得到了缠绕成型三维工艺窗口。同时，以控制工艺参数为目的，对影响制品性能的工艺参数控制机构进行分析，建立了平行辊纠偏机构的布带缠绕纠偏系统模型。结果显示：采用模糊控制器对布带缠绕纠偏系统进行控制，纠偏精度可达到0.6mm。此外，为达到压力的精确控制，提出基于参数估算的遗忘因子递推最小二乘法PID控制器的斜缠绕柔性压力-位置控制系统，使斜缠绕成型系统近似为单输入单输出的线性系统。通过参数估计算法实时更新控制器参数，调节缠绕位置，保持压辊与缠绕层的均匀接触，并实现缠绕压力的准确控制。在实现参数控制的基础上，提出了控制参数响应时序的控制方法；通过调整缠绕机DCS参数的通讯比例，优先级较高的敏感参数张力、压力平均响应时间被缩短，而优先级较低的搭接温度及缠绕温度平均响应时间被延长。