本文選題：纖維增強(qiáng)聚合物 + 注塑成型　； 參考：《南昌大學(xué)》2017年博士論文

【摘要】：本文針對(duì)纖維增強(qiáng)聚合物復(fù)合材料注塑成型技術(shù)的若干關(guān)鍵問(wèn)題進(jìn)行深入研究,以期獲得相關(guān)成型理論知識(shí),指導(dǎo)提升成型制品質(zhì)量。本文主要研究?jī)?nèi)容概要如下:1.搭建了纖維增強(qiáng)聚合物復(fù)合材料注塑成型實(shí)驗(yàn)裝置,設(shè)計(jì)加工了較復(fù)雜結(jié)構(gòu)的注塑成型模具,完成了注塑成型實(shí)驗(yàn)裝置的安裝和調(diào)試,并進(jìn)行了相關(guān)實(shí)驗(yàn)研究;基于較全面考慮注塑成型過(guò)程中形成的殘余應(yīng)力場(chǎng)、溫度場(chǎng)、纖維增強(qiáng)聚合物復(fù)合材料的非均勻各向異性熱力學(xué)屬性,建立了纖維增強(qiáng)聚合物復(fù)合材料注塑成型流動(dòng)和熱應(yīng)力分析的三維耦合有限元總翹曲變形預(yù)測(cè)模型。模擬算例與實(shí)驗(yàn)結(jié)果對(duì)比表明:注塑件翹曲變形朝著無(wú)加強(qiáng)筋一側(cè),形成中間低四周高的“拱形”結(jié)構(gòu),預(yù)測(cè)值與實(shí)驗(yàn)結(jié)果變化趨勢(shì)一致,運(yùn)用該模型能提升翹曲變形的預(yù)測(cè)精度,表明該預(yù)測(cè)模型的有效性。2.圍繞注塑成型過(guò)程中聚合物熔體模腔充填和纖維取向的核心問(wèn)題,從粘性流體動(dòng)力學(xué)理論出發(fā),分析纖維增強(qiáng)聚合物復(fù)合材料注塑成型熔體流動(dòng)基本控制方程;針對(duì)長(zhǎng)纖維增強(qiáng)聚合物復(fù)合材料注塑成型的特點(diǎn),研究注塑成型過(guò)程中的纖維分布規(guī)律,著重分析和探討主要工藝參數(shù)對(duì)纖維分布的影響機(jī)理;基于復(fù)合材料力學(xué)性能均勻化理論,建立長(zhǎng)纖維增強(qiáng)聚合物復(fù)合材料的非線性彈塑性本構(gòu)模型,結(jié)合耦合有限元分析方法,研究了不同本構(gòu)模型對(duì)翹曲變形計(jì)算結(jié)果的差異,分析主要纖維參數(shù)對(duì)翹曲變形的影響規(guī)律。研究結(jié)果表明:(1)注射時(shí)間對(duì)纖維取向分布的影響最為顯著,澆口附近是長(zhǎng)短纖維共存區(qū),近壁面附近纖維較長(zhǎng);隨著注射時(shí)間的減小或模具溫度的升高,纖維取向值和纖維長(zhǎng)度均減小;隨著熔體溫度的升高,纖維取向值減小,但纖維長(zhǎng)度則先減小后增大;隨著保壓壓力的增加,纖維長(zhǎng)度減小,保壓壓力對(duì)纖維取向的影響與速度/壓力轉(zhuǎn)化有關(guān)。以上結(jié)果與文獻(xiàn)結(jié)論總體一致。(2)基于彈性和彈塑性本構(gòu)模型計(jì)算的注塑件翹曲變形形狀均為中間高四周低的“拱形”結(jié)構(gòu),前者比后者的最大翹曲變形量小約18%,模擬結(jié)果與理論分析相符;隨著纖維初始長(zhǎng)度、長(zhǎng)徑比和纖維含量的增加,最大翹曲變形量均隨之減小。3.基于有限元數(shù)值模擬技術(shù),綜合考慮壁面滑移速度和壓力對(duì)粘度的影響,建立了薄壁注塑流動(dòng)三維數(shù)值模型,通過(guò)實(shí)驗(yàn)結(jié)果對(duì)比,驗(yàn)證數(shù)值模型的可靠性,考察是否考慮壁面滑移對(duì)熔體模腔充填速度分布的影響,分析壁面滑移和粘度的壓力依賴性對(duì)薄壁模腔熔體充填的影響,從理論上分析和解釋其影響機(jī)理。數(shù)值模擬與實(shí)驗(yàn)結(jié)果對(duì)比表明:只有同時(shí)考慮壁面滑移和粘度的壓力依賴性才能更好地預(yù)測(cè)薄壁注塑成型流動(dòng)過(guò)程,忽略壁面滑移或粘度的壓力依賴性,對(duì)薄壁注塑成型過(guò)程均有不同程度的影響。上述研究有助于對(duì)薄壁注塑成型理論及較之傳統(tǒng)注塑成型固有特性的認(rèn)識(shí)提供理論參考。4.在三維薄壁注塑流動(dòng)數(shù)值模型得到驗(yàn)證的基礎(chǔ)上,研究壁面滑移和粘度的壓力依賴性,對(duì)纖維增強(qiáng)聚合物復(fù)合材料薄壁注塑成型纖維取向和翹曲變形的影響,分析不同模型簡(jiǎn)化條件對(duì)數(shù)值模擬結(jié)果的影響,并從理論上探明其影響機(jī)理,研究主要注塑成型工藝參數(shù)對(duì)纖維增強(qiáng)聚合物復(fù)合材料薄壁注塑件的纖維取向分布,以及最大翹曲變形量的影響。研究結(jié)果表明:(1)通過(guò)與實(shí)驗(yàn)結(jié)果對(duì)比,考慮壁面滑移和粘度壓力依賴性的三維數(shù)值模擬,能較好地?fù)渥胶穸确较虻睦w維取向分布,忽略壁面滑移或壓力對(duì)粘度的影響,對(duì)纖維取向分布均有不同程度的影響,基于常規(guī)Hele-Shaw薄壁近似計(jì)算的芯層纖維取向分布與實(shí)際差異較大。(2)注射速率對(duì)纖維取向的影響最大,熔體溫度次之,模具溫度、保壓壓力和保壓時(shí)間對(duì)纖維取向的影響較小。(3)隨著注射速率,熔體溫度,模具溫度的增加,最大翹曲變形量均隨之增大,但注射速率達(dá)到一定值后影響減小;隨著保壓壓力的增加,最大翹曲變形量減小;保壓時(shí)間對(duì)最大翹曲變形量的影響較小。
[Abstract]:In this paper, some key problems in the injection molding of fiber reinforced polymer composites are studied in order to obtain relevant theoretical knowledge and guide the quality of molding products. The main contents of this paper are as follows: 1. the experimental device for the injection molding of fiber reinforced polymer composites is set up, and the design and processing are more complex. The injection molding mold of mixed structure has completed the installation and debugging of the injection molding experimental device, and carried out the related experimental research. Based on the comprehensive consideration of the residual stress field, the temperature field and the non-uniform anisotropy of the fiber reinforced polymer composites, the fiber reinforced polymer complex is established. The three dimensional coupled finite element warpage prediction model is used to predict the flow and thermal stress of the injection molding. The comparison of the simulation examples and the experimental results shows that the warpage of the injection parts is facing the non reinforcement side, forming a "arch" structure with low middle height in the middle, and the prediction value is in accordance with the experimental results, and the model can be used to improve the warpage. The prediction accuracy of the curved deformation indicates that the validity of the prediction model is.2. around the core problem of the filling and fiber orientation of the polymer melt in the injection molding process. Based on the viscous fluid dynamics theory, the basic control equation of the melt flow in the injection molding of the fiber reinforced polymer composite is analyzed. The distribution of fiber in the injection molding process is studied, and the influence mechanism of the main process parameters on the fiber distribution is analyzed and discussed. The non linear elastoplastic constitutive model of the long fiber reinforced polymer composites is established based on the homogenization theory of the mechanical properties of the composite materials, and the coupled finite element analysis is combined with the coupled finite element analysis. Method, the difference of warpage calculation results of different constitutive models was studied, and the effect of main fiber parameters on Warpage was analyzed. The results showed that: (1) the effect of injection time on fiber orientation distribution was the most significant, near the gate was long short fiber coexistence area, fiber near the near wall surface was longer, with the injection time decreasing or With the increase of die temperature, the fiber orientation value and fiber length decrease. With the increase of the melt temperature, the fiber orientation value decreases, but the fiber length decreases first and then increases. With the increase of pressure pressure, the fiber length decreases, and the influence of the pressure on the fiber orientation is related to the speed / pressure transformation. The above results are generally with the literature conclusion. (2) the warpage shapes of injection molded parts based on elastic and elastoplastic constitutive models are all "arch" structures with low middle and low middle, the former is about 18% smaller than the latter, and the simulation results agree with the theoretical analysis. With the increase of fiber initial length, length diameter ratio and fiber content, the maximum warpage deformation is all followed. .3. based on the finite element numerical simulation technology and considering the influence of the wall slip velocity and pressure on the viscosity, a three-dimensional numerical model of the thin wall injection flow is established. By comparing the experimental results, the reliability of the numerical model is verified. The effect of the wall slip on the velocity distribution of the melt cavity filling is considered, and the wall slip and the wall slip are analyzed. The effect of pressure dependence of viscosity on melt filling of thin-walled mold cavity is analyzed and explained theoretically. The comparison between numerical simulation and experimental results shows that the pressure dependence of wall slip and viscosity can be better predicted by considering the pressure dependence of wall slip and viscosity at the same time, and the pressure dependence of wall slip or viscosity is ignored. This study provides a theoretical reference for the theory of thin-walled injection molding and the understanding of the inherent characteristics of the traditional injection molding. Based on the verification of the numerical model of three-dimensional thin wall injection flow, the pressure dependence of the slip and viscosity of the wall is studied and the fiber reinforced.4. is reinforced. The influence of the fiber orientation and warp deformation on the thin wall injection molding of polymer composites is analyzed. The influence of different model simplification conditions on the numerical simulation results is analyzed, and the influence mechanism is explored theoretically. The fiber orientation distribution and the maximum warping of the main injection molding process parameters to the fiber reinforced polymer composite thin wall injection molding parts are studied. The results show that: (1) by comparing with the experimental results, the three-dimensional numerical simulation of wall slip and viscosity pressure dependence can be used to catch the fiber orientation distribution in the thickness direction better, neglecting the effect of wall slip or pressure on the viscosity, and to varying degrees of influence on the fiber orientation distribution, based on the conventional Hele The orientation distribution of core fiber in the -Shaw thin wall approximate calculation is different from the actual difference. (2) the injection rate has the greatest influence on the fiber orientation, the melt temperature is the second, the mold temperature, the pressure holding pressure and the holding time have little effect on the fiber orientation. (3) the maximum warping deformation increases with the injection rate, the melting temperature and the mold temperature. It is large, but the effect decreases after the injection rate reaches a certain value, and the maximum warpage deformation decreases with the increase of pressure protection pressure, and the influence of pressure holding time on the maximum warpage is less.
【學(xué)位授予單位】：南昌大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2017
【分類號(hào)】：TQ327;TB332

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