GFRP层合板厚板VIMP制备工艺与力学性能尺寸效应研究
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摘要
工程复合材料构件正在逐渐由小型化向大型化转变。近年来典型巨型玻璃纤维增强聚合物基复合材料(GFRP)工程构件——风力发电机叶片的研发和生产发展迅速,所用层合板部件的厚度和尺寸不断增大。本文在相关课题的支撑下对大尺寸GFRP厚板构件的真空灌注模塑成型(VIMP)工艺和性能表征方面的特殊性展开研究,包括大尺寸GFRP厚板构件VIMP工艺树脂灌注过程、GFRP厚板VIMP工艺固化过程温度分布和固化度分布、VIMP工艺成型GFRP层合板和含孔层合板的静态力学性能厚度尺寸效应等。
首先,对大尺寸GFRP厚板构件的VIMP工艺树脂灌注过程展开研究。VIMP工艺灌注过程主要的控制参数是温度和流道布设。本文选择Huntsman1564/3486和惠利LT5078A/5078B-2两种具有代表性的VIMP工艺用环氧树脂体系,分析结果表明二者均属于添加活性稀释剂改性的低粘度双酚A环氧/混胺反应体系,固化反应级数分别为0.905和0.88。基于等温粘度-时间数据建立两种树脂体系的Dual-Arrhenius流变模型和工程粘度模型,用于描述树脂体系流变行为,并联立两种模型对树脂体系VIMP工艺窗口进行了预报,确定最佳灌注温度为35℃。随后,研究了GFRP大型工程构件常用的三种玻璃纤维增强织物:[0] UD织物、[0/45/-45]三轴向织物和[0/45/90/-45]四轴向织物的渗流特性和VIMP工艺用导流介质对流动行为的影响,根据结果确定了流道布设原则。对典型大尺寸厚板工程构件——40m长某型风机叶片叶根段和大梁的VIMP灌注工艺实践进行了指导,构件浸渍情况良好。
其次,对GFRP厚板的VIMP工艺树脂固化过程温度分布和固化度分布展开研究。采用外推法确定了环氧树脂体系的固化特征温度,考察了最佳固化温度下厚板厚度方向温度分布。结果表明厚度的增加导致厚度方向温度差异和峰值温度增大,为避免过高峰值温度,厚板固化应分为预固化和固化两段进行。为研究温度差异对固化度分布的影响,本文提出了时间离散分步计算法,将一般基于等温条件建立的固化度模型应用范围扩展到非等温条件。建立了本文研究用环氧树脂树脂的两种等温条件下的固化度模型:Kamal模型和根据本文实验数据进行了修正的Olivier模型。采用时间离散分步计算法,计算了动态升温条件下的固化度-时间关系,计算值和实验值符合良好;固化起始阶段Kamal模型预测精度更高,固化反应后期尤其是最终固化度到达时间的预测,修正的Olivier模型精度更高。对典型厚板构件——85mm厚某型风机叶片叶根段小型试件厚度方向的固化度分布进行了计算。结果表明厚板预固化阶段依靠自身放热已达到较高固化度,温度差异导致的固化度差异可通过最佳固化温度下短时固化的方式消除,固化时间可根据计算结果确定。
再次,从纤维含量、拉伸性能、短梁剪切性能、弯曲性能四个方面,对VIMP工艺成型多轴向织物增强GFRP层合板的厚度尺寸效应进行了实验研究和总结。结果显示纤维体积分数在厚度方向上均匀分布;当厚度大于10mm时,纤维体积分数不随织物铺层数目的增加而变化,[0]、[0/45/-45]和[0/45/90/-45]织物增强层合板的纤维体积分数分别稳定在57%、57%和54.5%。力学性能实验结果显示模量与试样尺寸基本无关,强度随试样厚度和尺寸的增大而下降,可应用Weibull概率模型描述强度尺寸效应,模型与实验值符合良好。[0]、[0/45/-45]和[0/45/90/-45]织物增强层合板拉伸强度尺寸效应Weibull模量分别为39.2、37.6和25.3;短梁剪切强度尺寸效应Weibull模量分别为39.7、38.3和27.6;弯曲强度尺寸效应Weibull模量分别为35.4、28.0和21.3。本文实验获得的强度尺寸效应Weibull模型可为大尺寸GFRP复合材料构件的工程设计提供有效的参考。
最后,对VIMP工艺成型多轴向织物增强GFRP含孔层合板准静态拉伸强度厚度尺寸效应进行了研究。采用有限元方法分析了铺层数和厚度的增加对[0]和[0/45/-45]织物增强含孔层合板拉伸应力场的影响,结果显示其对拉伸应力场基本形态影响不大;[0]织物增强含孔层合板铺层数增加对孔周最大拉应力值和孔周应力集中因子的影响很小;而[0/45/-45]织物增强含孔层合板孔周最大拉应力值和孔周应力集中因子则随铺层数的增加而上升,上升趋势符合Boltzmann公式。实验研究了含孔层合板的拉伸强度厚度尺寸效应,结果显示孔径/板宽比分别为30mm/60mm和36mm/60mm时,[0]织物增强含孔层合板的Weibull模量分别为33.9和31.6,[0/45/-45]织物增强含孔层合板分别为26.4和20.8,均明显低于完好层合板Weibull模量值。厚度变化对含孔层合板强度比的影响并不明显。
The engineering composite components are developing from miniaturization to maximization recently. For the past few years, the development and production of the typical Glass Fibre Reinforced Polymer (GFRP) engineering composite components–wind turbine blades were booming, which cause the engineering GFRP laminates to be much larger and thicker. In this paper, the particularities of the large size GFRP thick laminates were focused on systematically, including the Vacuum Infusion Moulding Process (VIMP) technique used for the laminates components manufacture, the temperature distribution and the degree of cure distribution in laminates curing process, the size effects in mechanical properties test of laminates and open-hole laminates specimens.
Firstly, researches have been made about the resin infusion process of VIMP technique. The mainly controlling parameters of the infusion process are resin infusion temperature and design of flow channel layout. The Huntsman 1564/3486 and the huili LT5078A/5078B-2 epoxy resin systems were chosen as the laminates matrix. Analysis results show that both of them are the modified low viscosity bisphenol A epoxy/ multi-amine reaction systems, the reaction orders are 0.905 and 0.88. The Dual- Arrhenius rheological model and engineering viscosity model were established. These two kinds of models were combined to predict the VIMP processing windows of resin systems. Then the optimum resin infusion temperature was obtained to be 35℃. The permeability of the [0], [0/45/-45] and [0/45/90/-45] multi-axial fabric reinforcement, and the effects of the distribution medium on the resin flow behavior in VIMP had been studied. According to the results, the design principles of the resin flow channel layout were determined and applied to guide the VIMP infusion process of the root and the spar cap of a typical 40m length wind turbine blades.
Secondly, the distribution of the temperature and the degree of cure in thick laminates VIMP curing process were studied. The curing characteristic temperatures for the epoxy resin system was gotten by differential scanning calorimeter (DSC) technique at different heating rates. The distribution of the temperature during thick laminates curing process was inspected. The results showed that the temperature gradient at different thickness positions was increasing with the laminate thickness. To avoid the high peak temperature, the thick laminate curing process should be divided into two stages, the pre-curing stage and the curing stage. In order to study the distribution of the degree of cure, the Method of Accumulation by Time Dispersing Steps was proposed to calculate the degree of cure under non-isothermal conditions with the isothermal models-the Kamal kinetic model and the modified Olivier model. The relationship between degree of cure and time under non-isothermal conditions was calculated and verified by the experimental data. It shows that Kamal kinetic model is more accurate in the earlier stage of the curing course, while the modified Olivier model is more accurate in the later stage, especially at the final degree of cure. In the curing process of a typical engineering thick laminates components-the root of a wind turbine blade whose thickness is 85mm, the distribution of the degree of cure was calculated and analyzed. The results showed that the thick laminates could achieve high degree of cure in the pre-cure stage by self-heating, but there were differences of real time degree of cure in thickness direction. The high equivalent degree of cure could be achieved in the cure stage, the time of which could be determined by the calculation results.
Thirdly, the size effects were studied and summarized systematically from four aspects: the fibre volume fraction, the tensile test, the short- beam shear test and the flexural test of the multi-axial fabrics reinforced laminates manufactured by VIMP. The fibre volume fraction of the thick laminates uniformly distributes in the thickness direction, and do not change with the thickness when the thickness is higher than 10mm. The fibre volume fractions of [0], [0/45/-45] and [0/45/90/-45] fabric reinforced laminates are 57%, 57% and 54.5% respectively. The mechanical properties experiments show that the modulus doesn’t change with the size of the specimen, while the strength is decreasing with the size grows. Compared with the experimental data, the result shows that the Weibull model is fit for describing the strength size effects. The tensile strength Weibull moduli of [0], [0/45/-45] and [0/45/90/-45] fabrics reinforced laminates are 39.2, 37.6 and 25.3 respectively, while the short-beam shear strength Weibull moduli of them are 39.7, 38.3 and 27.6 respectively, and the flexural strength Weibull moduli of them are 35.4, 28.0 and 21.3 respectively. The Weibull moduli obtained from the experimental data could be useful for design of large size engineering composite components.
Fourthly, the size effects of the quasi-static tensile strength of the open-hole laminates specimen were studied by Finite Element Method (FEM) and experiment. The tensile stress fields of [0] and [0/45/-45] fabrics reinforced laminates open-hole specimens with different thicknesses were calculated with the FEM method and the results show that the growth of the number of layers and the thickness has little influence on the stress distribution. The maximum tensile stress SX and the stress concentrate factor K around the hole of the [0] fabric reinforced laminates are of little change with the growth of the number of layers, while the maximum SX and K of the [0/45/-45] fabric reinforced laminates is increasing with the growth of the number of layers and the Boltzmann formula is fit for describing the increasing speed. The experimental results show that when the hole diameter/ width is 30mm/60mm, the tensile strength Weibull modulus of [0] fabric reinforced laminates open-hole specimen is 33.9, of [0/45/-45] fabric reinforced laminates is 31.6; and when the hole diameter/ width is 36mm/60mm, the Weibull moduli are 26.4 and 20.8. The tensile strength Weibull moduli of the open-hole laminates are obviously less than that of the imperforate laminates correspondingly. It’s also found that the ratio of the open-hole laminates strength versus imperforate laminates strength is of little change with the growth of the thickness through the experimental data.
首先,对大尺寸GFRP厚板构件的VIMP工艺树脂灌注过程展开研究。VIMP工艺灌注过程主要的控制参数是温度和流道布设。本文选择Huntsman1564/3486和惠利LT5078A/5078B-2两种具有代表性的VIMP工艺用环氧树脂体系,分析结果表明二者均属于添加活性稀释剂改性的低粘度双酚A环氧/混胺反应体系,固化反应级数分别为0.905和0.88。基于等温粘度-时间数据建立两种树脂体系的Dual-Arrhenius流变模型和工程粘度模型,用于描述树脂体系流变行为,并联立两种模型对树脂体系VIMP工艺窗口进行了预报,确定最佳灌注温度为35℃。随后,研究了GFRP大型工程构件常用的三种玻璃纤维增强织物:[0] UD织物、[0/45/-45]三轴向织物和[0/45/90/-45]四轴向织物的渗流特性和VIMP工艺用导流介质对流动行为的影响,根据结果确定了流道布设原则。对典型大尺寸厚板工程构件——40m长某型风机叶片叶根段和大梁的VIMP灌注工艺实践进行了指导,构件浸渍情况良好。
其次,对GFRP厚板的VIMP工艺树脂固化过程温度分布和固化度分布展开研究。采用外推法确定了环氧树脂体系的固化特征温度,考察了最佳固化温度下厚板厚度方向温度分布。结果表明厚度的增加导致厚度方向温度差异和峰值温度增大,为避免过高峰值温度,厚板固化应分为预固化和固化两段进行。为研究温度差异对固化度分布的影响,本文提出了时间离散分步计算法,将一般基于等温条件建立的固化度模型应用范围扩展到非等温条件。建立了本文研究用环氧树脂树脂的两种等温条件下的固化度模型:Kamal模型和根据本文实验数据进行了修正的Olivier模型。采用时间离散分步计算法,计算了动态升温条件下的固化度-时间关系,计算值和实验值符合良好;固化起始阶段Kamal模型预测精度更高,固化反应后期尤其是最终固化度到达时间的预测,修正的Olivier模型精度更高。对典型厚板构件——85mm厚某型风机叶片叶根段小型试件厚度方向的固化度分布进行了计算。结果表明厚板预固化阶段依靠自身放热已达到较高固化度,温度差异导致的固化度差异可通过最佳固化温度下短时固化的方式消除,固化时间可根据计算结果确定。
再次,从纤维含量、拉伸性能、短梁剪切性能、弯曲性能四个方面,对VIMP工艺成型多轴向织物增强GFRP层合板的厚度尺寸效应进行了实验研究和总结。结果显示纤维体积分数在厚度方向上均匀分布;当厚度大于10mm时,纤维体积分数不随织物铺层数目的增加而变化,[0]、[0/45/-45]和[0/45/90/-45]织物增强层合板的纤维体积分数分别稳定在57%、57%和54.5%。力学性能实验结果显示模量与试样尺寸基本无关,强度随试样厚度和尺寸的增大而下降,可应用Weibull概率模型描述强度尺寸效应,模型与实验值符合良好。[0]、[0/45/-45]和[0/45/90/-45]织物增强层合板拉伸强度尺寸效应Weibull模量分别为39.2、37.6和25.3;短梁剪切强度尺寸效应Weibull模量分别为39.7、38.3和27.6;弯曲强度尺寸效应Weibull模量分别为35.4、28.0和21.3。本文实验获得的强度尺寸效应Weibull模型可为大尺寸GFRP复合材料构件的工程设计提供有效的参考。
最后,对VIMP工艺成型多轴向织物增强GFRP含孔层合板准静态拉伸强度厚度尺寸效应进行了研究。采用有限元方法分析了铺层数和厚度的增加对[0]和[0/45/-45]织物增强含孔层合板拉伸应力场的影响,结果显示其对拉伸应力场基本形态影响不大;[0]织物增强含孔层合板铺层数增加对孔周最大拉应力值和孔周应力集中因子的影响很小;而[0/45/-45]织物增强含孔层合板孔周最大拉应力值和孔周应力集中因子则随铺层数的增加而上升,上升趋势符合Boltzmann公式。实验研究了含孔层合板的拉伸强度厚度尺寸效应,结果显示孔径/板宽比分别为30mm/60mm和36mm/60mm时,[0]织物增强含孔层合板的Weibull模量分别为33.9和31.6,[0/45/-45]织物增强含孔层合板分别为26.4和20.8,均明显低于完好层合板Weibull模量值。厚度变化对含孔层合板强度比的影响并不明显。
The engineering composite components are developing from miniaturization to maximization recently. For the past few years, the development and production of the typical Glass Fibre Reinforced Polymer (GFRP) engineering composite components–wind turbine blades were booming, which cause the engineering GFRP laminates to be much larger and thicker. In this paper, the particularities of the large size GFRP thick laminates were focused on systematically, including the Vacuum Infusion Moulding Process (VIMP) technique used for the laminates components manufacture, the temperature distribution and the degree of cure distribution in laminates curing process, the size effects in mechanical properties test of laminates and open-hole laminates specimens.
Firstly, researches have been made about the resin infusion process of VIMP technique. The mainly controlling parameters of the infusion process are resin infusion temperature and design of flow channel layout. The Huntsman 1564/3486 and the huili LT5078A/5078B-2 epoxy resin systems were chosen as the laminates matrix. Analysis results show that both of them are the modified low viscosity bisphenol A epoxy/ multi-amine reaction systems, the reaction orders are 0.905 and 0.88. The Dual- Arrhenius rheological model and engineering viscosity model were established. These two kinds of models were combined to predict the VIMP processing windows of resin systems. Then the optimum resin infusion temperature was obtained to be 35℃. The permeability of the [0], [0/45/-45] and [0/45/90/-45] multi-axial fabric reinforcement, and the effects of the distribution medium on the resin flow behavior in VIMP had been studied. According to the results, the design principles of the resin flow channel layout were determined and applied to guide the VIMP infusion process of the root and the spar cap of a typical 40m length wind turbine blades.
Secondly, the distribution of the temperature and the degree of cure in thick laminates VIMP curing process were studied. The curing characteristic temperatures for the epoxy resin system was gotten by differential scanning calorimeter (DSC) technique at different heating rates. The distribution of the temperature during thick laminates curing process was inspected. The results showed that the temperature gradient at different thickness positions was increasing with the laminate thickness. To avoid the high peak temperature, the thick laminate curing process should be divided into two stages, the pre-curing stage and the curing stage. In order to study the distribution of the degree of cure, the Method of Accumulation by Time Dispersing Steps was proposed to calculate the degree of cure under non-isothermal conditions with the isothermal models-the Kamal kinetic model and the modified Olivier model. The relationship between degree of cure and time under non-isothermal conditions was calculated and verified by the experimental data. It shows that Kamal kinetic model is more accurate in the earlier stage of the curing course, while the modified Olivier model is more accurate in the later stage, especially at the final degree of cure. In the curing process of a typical engineering thick laminates components-the root of a wind turbine blade whose thickness is 85mm, the distribution of the degree of cure was calculated and analyzed. The results showed that the thick laminates could achieve high degree of cure in the pre-cure stage by self-heating, but there were differences of real time degree of cure in thickness direction. The high equivalent degree of cure could be achieved in the cure stage, the time of which could be determined by the calculation results.
Thirdly, the size effects were studied and summarized systematically from four aspects: the fibre volume fraction, the tensile test, the short- beam shear test and the flexural test of the multi-axial fabrics reinforced laminates manufactured by VIMP. The fibre volume fraction of the thick laminates uniformly distributes in the thickness direction, and do not change with the thickness when the thickness is higher than 10mm. The fibre volume fractions of [0], [0/45/-45] and [0/45/90/-45] fabric reinforced laminates are 57%, 57% and 54.5% respectively. The mechanical properties experiments show that the modulus doesn’t change with the size of the specimen, while the strength is decreasing with the size grows. Compared with the experimental data, the result shows that the Weibull model is fit for describing the strength size effects. The tensile strength Weibull moduli of [0], [0/45/-45] and [0/45/90/-45] fabrics reinforced laminates are 39.2, 37.6 and 25.3 respectively, while the short-beam shear strength Weibull moduli of them are 39.7, 38.3 and 27.6 respectively, and the flexural strength Weibull moduli of them are 35.4, 28.0 and 21.3 respectively. The Weibull moduli obtained from the experimental data could be useful for design of large size engineering composite components.
Fourthly, the size effects of the quasi-static tensile strength of the open-hole laminates specimen were studied by Finite Element Method (FEM) and experiment. The tensile stress fields of [0] and [0/45/-45] fabrics reinforced laminates open-hole specimens with different thicknesses were calculated with the FEM method and the results show that the growth of the number of layers and the thickness has little influence on the stress distribution. The maximum tensile stress SX and the stress concentrate factor K around the hole of the [0] fabric reinforced laminates are of little change with the growth of the number of layers, while the maximum SX and K of the [0/45/-45] fabric reinforced laminates is increasing with the growth of the number of layers and the Boltzmann formula is fit for describing the increasing speed. The experimental results show that when the hole diameter/ width is 30mm/60mm, the tensile strength Weibull modulus of [0] fabric reinforced laminates open-hole specimen is 33.9, of [0/45/-45] fabric reinforced laminates is 31.6; and when the hole diameter/ width is 36mm/60mm, the Weibull moduli are 26.4 and 20.8. The tensile strength Weibull moduli of the open-hole laminates are obviously less than that of the imperforate laminates correspondingly. It’s also found that the ratio of the open-hole laminates strength versus imperforate laminates strength is of little change with the growth of the thickness through the experimental data.
引文
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