Strain Path Control and Defect Formation and Suppression During Forming of Highly Contoured Composite Parts Using Active Tooling

使用主动模具成型高轮廓复合材料零件期间的应变路径控制以及缺陷形成和抑制

• 批准号: 0300268
• 负责人: Daniel Walczyk
• 金额: $ 30.39万
• 依托单位: Rensselaer Polytechnic Institute
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2003
• 资助国家: 美国
• 起止时间: 2003-04-15 至 2007-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0300268&HistoricalAwards=false
• 关键词: Strain; Path; Control; Defect; Formation

Complex products requiring a large number of high-performance parts characterize the aerospace industry, but this product complexity is contrasted by an extremely low volume throughput. For aerospace applications, advanced composite materials offer a number of advantages over metals including relatively high specific strengths and elastic moduli, which can lead to tailoring of shape and microstructure to meet performance requirements. Unfortunately, the use of composite parts in this industry has been severely limited by the prohibitive fabrication cost and time of advanced composite component, along with the need to store and maintain many under-utilized molds at great expense. In response to this need, the use of active discrete tooling (i.e., matrix of pins tooling that changes shape during the forming process based on electronically stored geometry) for composites forming is currently being considered. Recently, the PIs have successfully demonstrated that (1) composite forming using active tooling is possible and (2) it increases the number of components that can be successfully manufactured by the forming process. In addition, mold development and storage is greatly simplified because a single reconfigurable tool is used. This 3-year project sponsored by the National Science Foundation will seek to develop a fundamental understanding of composites forming process with active tooling, emphasizing particularly the effects of process variables on part formability and fiber reorientation. The research will concentrate on process development and on developing mathematical models and numerical modeling schemes that relate the material deformation modes necessary to form complex shapes, to advanced forming techniques and geometric features. The project includes support from Northrop Grumman in the form of materials testing, expertise in composites forming, and access to a larger reconfigurable tool, resulting in more rapid technology transfer to the aerospace industry. In addition, the proposal includes involvement of undergraduates (REU) and the integration of the research into specific undergraduate and graduate courses as case studies, semester design projects, and laboratory exercises. Overall, the proposed research has the potential to significantly improve part formability and reduce process time and cost for low to medium volume forming of relatively large parts from composite sheet. This can extend beyond aerospace to specialized automotive, marine, and biomedical applications. The research will also lead to improved simulation of composites forming, which is currently a major barrier to expanded use of composites.

复杂的产品需要大量的高性能部件，这是航空航天工业的特点，但这种产品的复杂性与极低的产量形成鲜明对比。 对于航空航天应用，先进复合材料提供了许多优于金属的优点，包括相对较高的比强度和弹性模量，这可以导致形状和微观结构的定制以满足性能要求。 不幸的是，复合材料部件在该工业中的使用受到高级复合材料部件的过高的制造成本和时间的严重限制，沿着的是需要以巨大的成本储存和维护许多未充分利用的模具。 响应于这种需要，使用主动离散工具（即，基于电子存储的几何形状在成形过程中改变形状的销工具矩阵）用于复合材料成形。最近，PI已经成功地证明了（1）使用主动工具的复合材料成形是可能的，（2）它增加了可以通过成形工艺成功制造的部件数量。 此外，由于使用了单个可重新配置的工具，模具开发和存储被大大简化。 这个由美国国家科学基金会赞助的为期3年的项目将寻求发展一个基本的理解复合材料成型过程中的主动模具，特别强调工艺变量对零件成形性和纤维重定向的影响。 该研究将集中在工艺开发和开发数学模型和数值建模方案，这些方案将形成复杂形状所需的材料变形模式与先进的成形技术和几何特征联系起来。该项目包括诺斯罗普·格鲁曼公司在材料测试、复合材料成型专业知识以及获得更大的可重构工具方面的支持，从而更快地将技术转移到航空航天工业。此外，该提案还包括本科生（REU）的参与，以及将研究整合到特定的本科生和研究生课程中，作为案例研究，学期设计项目和实验室练习。总的来说，所提出的研究有可能显着提高零件的可成形性，并减少工艺时间和成本的低到中等体积形成的相对较大的部分，从复合材料板。这可以从航空航天扩展到专门的汽车，船舶和生物医学应用。该研究还将改进复合材料成型的模拟，这是目前扩大复合材料使用的主要障碍。