二维三轴编织带缠绕碳纤维复合材料机匣包容性研究
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摘要
碳纤维复合材料由于具有高比强度、高比模量和耐腐蚀等优点而被广泛应用于航空航天领域。GE公司在新一代大涵道比商用航空发动机GEnx中使用了一种二维三轴碳纤维编织带缠绕复合材料机匣,并于2007年7月通过整机包容性适航试验,取得单机减重160kg的效果。航空发动机的叶片包容过程为典型的非规则高速撞击过程,而复合材料的高速冲击特性和动态响应比金属材料更加复杂,因此,系统深入的研究复合材料机匣的包容特性,对我国研制高性能大涵道比航空发动机具有十分重要的意义。本文结合试验、理论分析和数值仿真主要完成以下研究工作：
(1)进行数值仿真计算方法的研究。基于ANSYS/LS-DYNA软件,建立二维三轴编织复合材料单层靶板和多层靶板在弹体高速冲击下的数值仿真计算模型,包括纱线模型、单胞模型和连续介质模型。比较不同计算模型的仿真预测效果以及计算效率。结果表明,纱线模型可以有效的表现纱线的断裂失效、滑移、拔出等行为,但建模难度大,计算时间长；单胞模型和连续介质模型预测的失效模式主要表现为沿纵向和横向的裂纹,其中单胞模型可以表现编织纱线的铺设方向,比连续介质模型的描述更加接近实际,但靶板的抗弹性能预测和计算效率上相差不大,但连续介质模型建模更加方便,适合工程应用,因此在机匣包容性数值仿真中可使用连续介质模型。
(2)进行二维三轴编织复合材料层合靶板的弹道冲击特性研究。使用钛合金平头圆柱弹体和矩形叶片弹体进行对比试验,评估弹体形状差异对试验结果的影响。使用二维三轴编织布层合板与缎纹机织布层合板进行对比试验,研究碳纤维增强结构对复合材料靶板抗弹能力的影响。根据试验得到的复合材料靶板失效模式和失效区域形状,修改Lopez-Puente理论模型,建立弹体冲击靶板过程中能量对弹体位移的微分方程,有效的预测两种复合材料靶板的弹道极限。采用连续介质模型和连续损伤力学(Continum damage mechanism, CDM)材料模型,仿真分析二维三轴编织复合材料靶板受弹体高速冲击的过程及损伤机理。
(3)进行二维三轴编织带缠绕增强复合材料机匣的叶片包容性研究。在高速旋转试验台上使用TC4钛合叶片完成3次复合材料机匣包容性试验,获得了包容、接近临界包容和非包容三种典型的试验结果。结合试验和数值仿真,详细研究了高速旋转飞失叶片与机匣的撞击过程。采用数值仿真方法对影响机匣包容性的三个关键因素—机匣壁厚、叶片动能和冲击角度的影响进行了参数化分析,给出复合材料机匣壁厚的经验设计公式。
(4)进行二维三轴碳纤维编织复合材料机匣在大型航空发动机中的应用研究。针对某型航空发动机一级风扇,使用碳纤维增强复合材料叶片和二维三轴碳纤维编织带缠绕复合材料机匣代替原有的钛合金叶片和钛合金机匣,以期减轻重量并提高包容能力,使其满足适航要求。分别建立不同壁厚的风扇机匣的单叶片包容模型和三叶片包容模型,研究复合材料叶片与复合材料机匣的撞击过程,并对追随叶片的影响进行了分析。结果表明,使用复合材料机匣和叶片可有效的减轻风扇系统的重量,并且提高包容效率。
Carbon fiber Reinforced composites have been widely used in aerospace field due to its advantages of high specific strength, high specific modulus and corrosion resistance. The GE company employs2D carbon fiber tri-axial braided composites in the fan containment system on the GEnx engine. The usage of composite enables GEnx engine reducing weight about160kg and passing the full engine test in July2007. The containment process of the aero-engine fan case is a typical non-ideal high speed impact process. Besides, the impact characteristics and dynamic responses of the composite casing are more complicated than the metal casing. Thus investigating on the composite fan casing systematically and thoroughly have great significane for its application on the commercial aircraft engine. In the current dissertation, the following issues were studied in terms of experiments, theoretical analysis and numerical simulations:
(1) Investigation on the numerical simulation methods. Based on the commercial finite element codes ANSYS/LS-DYNA, the high velocity impact model of single layer and multi-layers triaxial braided composites were developed by virtue of three types of modeling methods, i.e. yarn model, unit cell model and continuum model. The numerical simulation results and the computation efficiency were compared for three methods. It is concluded that, the yarn model is efficient in predicting the fiber fracture failure, sliding and pull-out, but is difficult in modeling and cost greatly more computation time. The unit cell model and continuum model predicted similar failure modes-the cracking along the longitudinal and transverse direction. The unit cell model can describe the fiber orientation of braided fibers, thus is closer to the actual reinforced architecture. As the impact resistance performance and the computation efficiency predicted by the continuum model is very close to the unit cell model, but the continum model can be developed more convinently, and suitable for enginering application. In consequence, the continuum model was used in studying the high velocity impact response of composite casing.
(2) Investigation on the ballistic impact properties of the2D triaxial braided composite. Ballistic tests were conducted with the titanium flat-ended cylinder projectile and the rectangular blade-like projectile to evaluate the influences of the projectile shape on the test results. To figure out the influences of the carbon fiber reinforcement architecture on the ballistic performace, one type of satin woven laminated composites were also used in comparison tests. Based on the failure modes and damage area shape observed in tests, the Lopez-Puente model were modified, and the energy differential equation with repect to projectile displacement were established. The theoretical model was validated by predicting the ballistic limit correctly. In addition, the numerical model employing the CDM material model and continuum modeling method were used to study the impact process and the damage mechanism of the composite target.
(3) Investigation on the containment mechanism of the2D triaxial braided composite casing. Component containment tests were conducted on the high speed rotating machninery for the composite casing using TC4titanium blade. Three typical results were obtained in the tests, including contained result, near critical contained result and uncontained result. The impact process between the blade and the composite casing was analyzed by the numerical simulation results in combination of test results. Three crutial influencing factors-casing thickness, blade kinetic energy and the impact angle were analyzed in detail by parametric study, which derived the empirical designing equations for composite casing.
(4) Investigation on the engineering application of the2D triaxial braided composite casing on the large aircraft engine.The original titanium fan blade and stiffened casing were substituted for the composite fan blade and casing to improve the containment performance of the first stage fan containment system for a certain type aero-engine, and satisfy the demand of airworthiness regulation. A series of single blade and three blades containment finite element model were developed. The impact process between the composite fan blade and the braided compsite fan casing were analyzed, and the effects of the trailing blades on the containment process were also investigated. It is concluded that the using of the composite containment system can reduce weight of the aeroengine and improve the containment efficiency at the same time.
(1)进行数值仿真计算方法的研究。基于ANSYS/LS-DYNA软件,建立二维三轴编织复合材料单层靶板和多层靶板在弹体高速冲击下的数值仿真计算模型,包括纱线模型、单胞模型和连续介质模型。比较不同计算模型的仿真预测效果以及计算效率。结果表明,纱线模型可以有效的表现纱线的断裂失效、滑移、拔出等行为,但建模难度大,计算时间长；单胞模型和连续介质模型预测的失效模式主要表现为沿纵向和横向的裂纹,其中单胞模型可以表现编织纱线的铺设方向,比连续介质模型的描述更加接近实际,但靶板的抗弹性能预测和计算效率上相差不大,但连续介质模型建模更加方便,适合工程应用,因此在机匣包容性数值仿真中可使用连续介质模型。
(2)进行二维三轴编织复合材料层合靶板的弹道冲击特性研究。使用钛合金平头圆柱弹体和矩形叶片弹体进行对比试验,评估弹体形状差异对试验结果的影响。使用二维三轴编织布层合板与缎纹机织布层合板进行对比试验,研究碳纤维增强结构对复合材料靶板抗弹能力的影响。根据试验得到的复合材料靶板失效模式和失效区域形状,修改Lopez-Puente理论模型,建立弹体冲击靶板过程中能量对弹体位移的微分方程,有效的预测两种复合材料靶板的弹道极限。采用连续介质模型和连续损伤力学(Continum damage mechanism, CDM)材料模型,仿真分析二维三轴编织复合材料靶板受弹体高速冲击的过程及损伤机理。
(3)进行二维三轴编织带缠绕增强复合材料机匣的叶片包容性研究。在高速旋转试验台上使用TC4钛合叶片完成3次复合材料机匣包容性试验,获得了包容、接近临界包容和非包容三种典型的试验结果。结合试验和数值仿真,详细研究了高速旋转飞失叶片与机匣的撞击过程。采用数值仿真方法对影响机匣包容性的三个关键因素—机匣壁厚、叶片动能和冲击角度的影响进行了参数化分析,给出复合材料机匣壁厚的经验设计公式。
(4)进行二维三轴碳纤维编织复合材料机匣在大型航空发动机中的应用研究。针对某型航空发动机一级风扇,使用碳纤维增强复合材料叶片和二维三轴碳纤维编织带缠绕复合材料机匣代替原有的钛合金叶片和钛合金机匣,以期减轻重量并提高包容能力,使其满足适航要求。分别建立不同壁厚的风扇机匣的单叶片包容模型和三叶片包容模型,研究复合材料叶片与复合材料机匣的撞击过程,并对追随叶片的影响进行了分析。结果表明,使用复合材料机匣和叶片可有效的减轻风扇系统的重量,并且提高包容效率。
Carbon fiber Reinforced composites have been widely used in aerospace field due to its advantages of high specific strength, high specific modulus and corrosion resistance. The GE company employs2D carbon fiber tri-axial braided composites in the fan containment system on the GEnx engine. The usage of composite enables GEnx engine reducing weight about160kg and passing the full engine test in July2007. The containment process of the aero-engine fan case is a typical non-ideal high speed impact process. Besides, the impact characteristics and dynamic responses of the composite casing are more complicated than the metal casing. Thus investigating on the composite fan casing systematically and thoroughly have great significane for its application on the commercial aircraft engine. In the current dissertation, the following issues were studied in terms of experiments, theoretical analysis and numerical simulations:
(1) Investigation on the numerical simulation methods. Based on the commercial finite element codes ANSYS/LS-DYNA, the high velocity impact model of single layer and multi-layers triaxial braided composites were developed by virtue of three types of modeling methods, i.e. yarn model, unit cell model and continuum model. The numerical simulation results and the computation efficiency were compared for three methods. It is concluded that, the yarn model is efficient in predicting the fiber fracture failure, sliding and pull-out, but is difficult in modeling and cost greatly more computation time. The unit cell model and continuum model predicted similar failure modes-the cracking along the longitudinal and transverse direction. The unit cell model can describe the fiber orientation of braided fibers, thus is closer to the actual reinforced architecture. As the impact resistance performance and the computation efficiency predicted by the continuum model is very close to the unit cell model, but the continum model can be developed more convinently, and suitable for enginering application. In consequence, the continuum model was used in studying the high velocity impact response of composite casing.
(2) Investigation on the ballistic impact properties of the2D triaxial braided composite. Ballistic tests were conducted with the titanium flat-ended cylinder projectile and the rectangular blade-like projectile to evaluate the influences of the projectile shape on the test results. To figure out the influences of the carbon fiber reinforcement architecture on the ballistic performace, one type of satin woven laminated composites were also used in comparison tests. Based on the failure modes and damage area shape observed in tests, the Lopez-Puente model were modified, and the energy differential equation with repect to projectile displacement were established. The theoretical model was validated by predicting the ballistic limit correctly. In addition, the numerical model employing the CDM material model and continuum modeling method were used to study the impact process and the damage mechanism of the composite target.
(3) Investigation on the containment mechanism of the2D triaxial braided composite casing. Component containment tests were conducted on the high speed rotating machninery for the composite casing using TC4titanium blade. Three typical results were obtained in the tests, including contained result, near critical contained result and uncontained result. The impact process between the blade and the composite casing was analyzed by the numerical simulation results in combination of test results. Three crutial influencing factors-casing thickness, blade kinetic energy and the impact angle were analyzed in detail by parametric study, which derived the empirical designing equations for composite casing.
(4) Investigation on the engineering application of the2D triaxial braided composite casing on the large aircraft engine.The original titanium fan blade and stiffened casing were substituted for the composite fan blade and casing to improve the containment performance of the first stage fan containment system for a certain type aero-engine, and satisfy the demand of airworthiness regulation. A series of single blade and three blades containment finite element model were developed. The impact process between the composite fan blade and the braided compsite fan casing were analyzed, and the effects of the trailing blades on the containment process were also investigated. It is concluded that the using of the composite containment system can reduce weight of the aeroengine and improve the containment efficiency at the same time.
引文
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