电磁铆接技术在复合材料结构中的应用研究
摘要
复合材料具有高比强度、高比模量、良好的抗疲劳性、抗腐蚀性等一系列优点，在现代航空航天结构中得到广泛应用。与金属结构相比，复材结构的连接是其薄弱环节，结构破坏的60％～80％发生在连接处。与螺接相比，铆接具有接头重量轻、工艺简单、成本低等一系列优点，然而由于复合材料层间强度低，抗冲击能力差，普通铆接容易造成安装损伤。电磁铆接作为一种新型铆接工艺方法，可以克服传统锤击铆接的缺点而充分发挥铆接的技术经济优势。本文对电磁铆接在复合材料中的应用进行了具体研究。
文章第一部分针对带垫圈的复合材料铆接件的特点，结合电磁铆接技术特点及复合材料破坏机理，安排了铆接试验，并通过对初始孔进行损伤检测来严格确保铆接孔的质量。通过工艺参数试验，得出了垫圈尺寸、铆钉外伸量、钉孔间隙等参数，经损伤检测分析，此参数选择合理。
接下来对平面复合材料双埋头铆接结构进行了试验分析，对铆接时造成其孔壁损伤的可能性进行了分析，并针对具体结构，通过试验得出了锪窝深度、钉孔间隙、铆钉外伸量、相对干涉量等工艺参数，损伤检测结果表明，这些参数可应用于实际生产。
针对飞机鸭翼、内外副翼、腹鳍以及方向舵等实际结构，研究了斜面双埋头复材结构的电磁铆接工艺，提出斜面双埋头结构铆接存在的问题并给出合理的技术措施，即使用斜面铆卡和控制铆钉外伸量。
为了研究电磁铆接代替普通铆接的可行性，本文进行了抗拉和抗剪强度对比试验，试验结果表明，电磁铆接的铆接件的抗剪强度高于普通铆接的，其两种铆接方法所得铆接件的抗拉强度基本相似。研究表明由试验所得的工艺参数合理，电磁铆接可以代替普通铆接应用于实际生产。
最后，论文完成了复合材料结构件HB6478系列钛铆钉电磁铆接工艺规范的编制。
Composites have a series of merits, such as high specific strength, high specific modulus and fine characteristic of resisting fatigue and cautery etc, and get extensive use in modern aeronautic and astronautic structure. Compared with metal structure, the joint is weak position of composites where 60%～80% of structure breakages take place. Compared with bolt joint, riveting has many good characters such as light weight of connection, simple process and low cost, but general riveting made installation damage easily due to composites' low interlaminar strength and dispatch resistance impact ability .As a new technology, electromagnetic riveting(EMR) can overcome the shortcomings of traditional hammer riveting and exert the technology economic advantages of riveting. This thesis researched concretely on application of EMR in fiber composites structure.
In the first section, characters of composites riveting coupon with washer and EMR technique and elements of composites damage were analyzed, riveting experimentation was arranged, And Non-Destructive Inspection(NDI) was applied in the rivet hole in order to ensure the quality of hole strictly. The diameter of washer, the shank length of rivet and clearance of rivet hole were all got from craft experiments. The result of NDI indicated that the selected process parameter was proper.
Then the performance of riveting structure of flat composites with double sunk head and possibility of composites hole circumference damage brought in course of rivet joint were analyzed by experiments. Craft parameters such as the depth of countersink, appropriate gap between rivet and its hole and exterior length of rivet were obtained by experiments.
Orienting the framework of plane's canard wing、in-aileron、pelvic fin and rudder, the EMR craft on composites with incline structure was researched in the thesis, the problem that existed in riveting incline double sunk head structure was brought forward and techno-means were obtained that was to make use of incline rivet set cavity and control the shank length of rivet.
Some contrast experiments of the shearing strength and abruption intensity for
文章第一部分针对带垫圈的复合材料铆接件的特点，结合电磁铆接技术特点及复合材料破坏机理，安排了铆接试验，并通过对初始孔进行损伤检测来严格确保铆接孔的质量。通过工艺参数试验，得出了垫圈尺寸、铆钉外伸量、钉孔间隙等参数，经损伤检测分析，此参数选择合理。
接下来对平面复合材料双埋头铆接结构进行了试验分析，对铆接时造成其孔壁损伤的可能性进行了分析，并针对具体结构，通过试验得出了锪窝深度、钉孔间隙、铆钉外伸量、相对干涉量等工艺参数，损伤检测结果表明，这些参数可应用于实际生产。
针对飞机鸭翼、内外副翼、腹鳍以及方向舵等实际结构，研究了斜面双埋头复材结构的电磁铆接工艺，提出斜面双埋头结构铆接存在的问题并给出合理的技术措施，即使用斜面铆卡和控制铆钉外伸量。
为了研究电磁铆接代替普通铆接的可行性，本文进行了抗拉和抗剪强度对比试验，试验结果表明，电磁铆接的铆接件的抗剪强度高于普通铆接的，其两种铆接方法所得铆接件的抗拉强度基本相似。研究表明由试验所得的工艺参数合理，电磁铆接可以代替普通铆接应用于实际生产。
最后，论文完成了复合材料结构件HB6478系列钛铆钉电磁铆接工艺规范的编制。
Composites have a series of merits, such as high specific strength, high specific modulus and fine characteristic of resisting fatigue and cautery etc, and get extensive use in modern aeronautic and astronautic structure. Compared with metal structure, the joint is weak position of composites where 60%～80% of structure breakages take place. Compared with bolt joint, riveting has many good characters such as light weight of connection, simple process and low cost, but general riveting made installation damage easily due to composites' low interlaminar strength and dispatch resistance impact ability .As a new technology, electromagnetic riveting(EMR) can overcome the shortcomings of traditional hammer riveting and exert the technology economic advantages of riveting. This thesis researched concretely on application of EMR in fiber composites structure.
In the first section, characters of composites riveting coupon with washer and EMR technique and elements of composites damage were analyzed, riveting experimentation was arranged, And Non-Destructive Inspection(NDI) was applied in the rivet hole in order to ensure the quality of hole strictly. The diameter of washer, the shank length of rivet and clearance of rivet hole were all got from craft experiments. The result of NDI indicated that the selected process parameter was proper.
Then the performance of riveting structure of flat composites with double sunk head and possibility of composites hole circumference damage brought in course of rivet joint were analyzed by experiments. Craft parameters such as the depth of countersink, appropriate gap between rivet and its hole and exterior length of rivet were obtained by experiments.
Orienting the framework of plane's canard wing、in-aileron、pelvic fin and rudder, the EMR craft on composites with incline structure was researched in the thesis, the problem that existed in riveting incline double sunk head structure was brought forward and techno-means were obtained that was to make use of incline rivet set cavity and control the shank length of rivet.
Some contrast experiments of the shearing strength and abruption intensity for
引文
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[14] Hartmann, J., Brown, T., "Integration and Qualification of the HH500 Hand Operated Electromagnetic Riveting System on the 747 Section 11", SAE Aerofast Conference. Wichita. September, 1993
[15] 曹增强．国外电磁铆接技术发展状况[J]．航空科学技术，1997(4)
[16] 赵渠森，杨国章等．复合材料的结构连接[J]．北京：国防工业出版社
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[18] Peter Zieve. Low Voltage Electromagnetic Riveter.SME, 1986.10
[19] Ho-Cheng H, Dharan C.Delamination during drilling in composite laminates. Trans ASME 1990; 112:239-9
[20] Zieve, P., Durack, L., Huffer, B., Brown, T., "Advanced EMR Technology ", SAE Aerofast Conference, Bellevue, October, 1992
[21] Hartmann, J., and Zieve, P., "Electroimpact Robot End Effecter," Manufacturing Processes, Systems and Machines, 14th Conference on Production Research and Technology; Society of Manufacturing Engineers, Dearborn, MI, October, 1987
[22] Townsend, Harry E., "The Life Cycle of a Production Process ASAT/EMR", SME Fastec'89, Arlington, October 1989
[23] 航空周刊．1996，7
[24] 李志尧，佘公藩等．应力波铆接[J]．航空制造工程，1988(2)
[25] 许国康．磁脉冲铆接技术在树脂基复合材料结构连接中的应用[C]．见：陈祥宝编，第十三届全国复合材料学术会议论文集．北京：航空工业出版社，2004
[26] 曹增强．电磁铆接技术研究[J]．航空学报，2004．1
[27] John Hartmann, Michael Assadi, Scott Tomchick, "Low Voltage Electromagnetic Lockbolt Installation", Electroimpact Ltd. Research Papers, 922406
[28] DeVlieg, R., "Lightweight Handheld EMR with Spring-Damper Handle", SAE Aerofast Conference, New Orleans, September, 2000
[29] Jeff A.Truess, Michael D.Assadi, John L.Hantmann, Emma King, Alan Minshull, "Flexible High Speed Riveting Machine", SAE International, 2003.11
[30] Wayne Perley, Peter Zieve, "Lightweight HH503 Handheld Riveter", Society of Automotive Engineers, 2002.6
[31] 卢维娴，陆在庆．钛合金应力波铆接中绝热剪切的显微分析[J]．爆炸与冲击，1982(1)
[32] 佘公藩等．应力波铆接装置的试验研究[J]．运输机工程，1989(2)
[33] 曹增强，陶华，佘公藩等．大直径铆钉的应力波铆接[J]．航空工艺技术，1990(8)：27～28
[34] John Hartmann. Development of the Handheld Low Voltage Electromanetic Riveter. SME Transaction 1990.11
[35] 曹增强. M.Cardew-Hall, Interference-fit riveting technique in fiber composite laminates, Aerospace Science and Technology,2006.1
[36] 汪裕炳，张全纯．复合材料的结构连接[M]．北京：国防工业出版社，1992
[37] Webb.A.L,Riveting and Bolting in Carbon Fibre Composite,B.Ae.Paper Form a Symposium entitled "Jointing in Fibre Reinforced Plastics",Sep,1978
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