分析六种最常见复合材料成型加工工艺的优缺点.docx

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1、分析六种最常见复合材料成型加工工艺的优缺点目录1. 序言1Prepreg/Autoclave （预浸料/高压釜） 32. Results：航空级41. 1.等级：中级技能43. 2. Resin Transfer Molding （树月旨传递模塑） 6Results：优秀的装饰品64. 1.技能等级：高技能64. 1. 1. Resin Infusion （树脂灌注） 8Results： 消费品等级84.1. 技能等级:中级技能85. 1. 1. Prepreg/Oven Cure （预浸料/烘箱 固化） 10Results ：消费品级104.2. 技能等级：中级技能106. 1. 1. Pr

2、ess Molding （模压成型）12Results：高度可预测的结果127. 1.技能水平：一般技能127. 1. 1. Wet Layup （湿4甫工艺）14Results：低等级148. 1.技能水平：低技能141.序言在本文中将从 Process、Results Materials Tooling、Operation Cost Equipment 等 6 个方面 对复合材料常见加工工艺Prepreg/Autoclave （预浸料/高压釜）、Resin Transfer Molding （RTM, 树脂传递模塑）、Resin Infusion （树脂灌注）、Prepreg/Oven C

3、ure （预浸料/烘箱固化）、Press Molding （模压成型）和WetLayup （湿铺工艺）进行定性定量比照评价。在6个方面进行定量评价时，以总分值10分为最高分、。分为最低分进行考量；其中Process过 程考量主要涉及Cleanliness （清洁度）、Volatile release （挥发剂释放）等6个方面；Results考量 涉及Repeatability （可重复性）、Void content （孔隙量）等10个方面;Materials考量涉及Cost of materials （材料本钱）等4个方面；Tooling考量涉及Tooling cost （工具本钱）等3个方面

4、； Operation Cost 涉及 Labor intensity （劳动强度）等 3 个方面；Equipment 考量涉及 Equipment第1页共15页5. 1. 1. Prepreg/Oven Cure （预浸料/烘箱固化）EquipmentEquipmentOperationCostPrepreg/Oven CureProcess 10 aResults 4I / X 01 I ，IJTooling电 磁纤维及其复合材料技术, MaterialsResults：消费品级5.1. 技能等级：中级技能构建预浸材料结构件并在烘箱中固化，将为具有正确技术技能和设施的人员提供消费品级的结

5、果，其挑战主要包括昂贵的材料和大量的劳动力，但设备比高压釜廉价。第10页共15页PREPREG/OVEN CURE第11页共15页ProcessProcess Score (higher is better)8.7CleanlinessMessy Ov10 Clean9Difficulty / Skill LevelDifficult 0 10 Easy4Secondary Ops, trimming etc.No Ops 0 10 More Ops10Volatile releaseOpen Air Ov10 None10Controlled cure cyclesNone 0 10 Con

6、trolled10Controlled resin contentNone 0 10 Controlled9ResultsResults Score (higher is better)8.1CompactionNone 0 10 Best6Complexity of partNone 0 10 Best6RepeatabilityNone 0 10 Best7Void ContentHigh 0 10 Low7Fiber Orientation ControlNone 0 10 Best10Resin RichnessHigh 0 10 Low9Repeatable Mechanical P

7、ropertiesLow 0 10 High9Controlled WeightLow 0 10 High10PorosityHigh 0 10 Low7Core Co-CuringBad 0 10 Good10|MatcfialsMaterials Score (higher is better)1.6Consumable costHigh 0 10 Low3Minimum Order Quantity of rnateridlsHigh 0 10 Low1Room temp cure resin systemsLow 0 10 HighCost of materialsHigh 0 10

8、Low3Shelf life of materialsLow 0 10 High1ToolingTooling Score (higher is better)3.3All surfaces are tooledOne 0 10 Multiple5；Tooling CostHiqh 0 10 Low3CTE issuesHiqh 0 10 Low2Operation CostOperation Score (higher is better)3.0Facility CostHiqh 0 10 Low4Facility DedicationHiah 0 10 Low2Labor Intensit

9、yHigh 0 10 Low3EquipmentEquipment Score (higher is better)3.71 Equipment ExpenseHiqh 0 10 Low3Dedicated unique equipmentHigh 0 10 LowI8 .Part limited to equipment sizeNone 0 10 Clean9Difficulty / Skill LevelDifficult 0 10 Easy7Secondary Ops, trimming etc.No Ops 0 10 More Ops3Volatile releaseOpen Air

10、 0 10 None3Controlled cure cyclesNone 0 10 Controlled10Controlled resin contentNone 0 10 Controlled8ResultsResults Score (higher is better)8.0CompactionNone 0 10 Best10Complexity of partNone 0 10 Best8RepeatabilityNone 0 10 Best9Void ContentHigh 0 10 Low9Fiber Orientation ControlNone 0 10 Best5Resin

11、 RichnessHigh 0 10 Low9Repeatable Mechanical PropertiesLow 0 10 High9Controlled WeightLow 0 10 High10PorosityHigh 0 10 Low9Core Co-CuringBad 0 10 Good一 2MaterialsMaterials Score (higher is better)3.0Consumable costHigh 0 10 Low10Minimum Order Quantity of materialsHigh 0 10 Low1Room temp cure resin s

12、ystemsLow 0 10 High0Cost of materialsHigh 0 10 Low3Shelf life of materialsLow 0 10 High1ToolingTooling Score (higher is better)5.0All surfaces are tooledOne 0 10 Multiple7Tooling CostHigh 0 10 Low1CTE issuesHigh 0 10 Low7Operation CostOperation Score (higher is better)4.3Facility CostHigh 0 10 Low4F

13、acility DedicationHigh 0 10 Low2Labor IntensityHigh 0 10 Low7EquipmentEquipment Score (higher is better)0.7Equipment ExpenseHigh 0 10 Low2Dedicated unique equipmentHigh 0 10 Low0Part limited to equipment sizeNone Ov*?碳咨簿收其复（材料按才7. 1. 1. Wet Layup （湿铺工艺）Wet LayupWet LayupProcess10 -ResultsMaterialsTo

14、oling、,文/碳纤维及其复合材料按方8. Results ：低等级8.1. 技能水平：低技能使用湿铺工艺制造复合材料结构件不会产生很好的效果，但它对初学者有好处，而且非常便 宜。它不需要专门的设施，材料本钱更低。第14页共15页WET LAYUP第15页共15页ProcessProcess Score (higher is better)2.3CleanlinessMessy 0 10 Clean1Difficulty / Skill LevelDifficult 0 10 Easy2Secondary Ops, trimming etc.No Ops 0 10 More Ops10Vol

15、atile releaseOpen Air 0 10 None0Controlled cure cyclesNone 0v10 Controlled0Controlled resin contentNone 0 10 Controlled1ResultsResults Score (higher is better)2.0CompactionNone 0 10 Best2Complexity of partNone 0 10 Best4RepeatabilityNone 0 10 Best2Void ContentHigh 0 10 Low1Fiber Orientation ControlN

16、one 0 10 Best1Resin RichnessHigh 0 10 Low0Repeatable Mechanical PropertiesLow 0 10 High1Controlled WeightLow 0 10 High2PorosityHigh 0v10 Low2Core Co-CuringBad 0 10 Good5MaterialsMaterials Score (higher is better)8.6Consumable costHigh 0v10 Low7Minimum Order Quantity of materialsHigh 0 10 Low9Room te

17、mp cure resin systemsLow 0 10 High10Cost of materialsHigh 0 10 Low9Shelf life of materialsLow 0 10 High8ToolingTooling Score (higher is better)6.0All surfaces are tooledOne 0 10 Multiple2Tooling CostHigh 0 10 Low7CTE issuesHigh 0 10 Low9Operation CostOperation Score (higher is better)6.0Facility Cos

18、tHigh 0 10 Low8Facility DedicationHigh 0 10 Low9Labor IntensityHigh 0 10 Low1EquipmentEquipment Score (higher is better)9.7Equipment ExpenseHigh 0 10 Low9Dedicated unique equipmentHigh 0 10 Low10Part limited to equipment sizeNone 0运履青嘴取其复印潴掇方expense （设备费用）等3个方面。图1和表1中汇总了6种常见复合材料加工工艺定量考核的指标，下面将针对这6种常

19、见工艺进行评述。Comparison of MethodsPP/AUTOPP/OVEN Wet PRESSProcess10.0EquipmentEquipmentOperation CostResultsMaterialsTooling主碳纤维及其复合材料宓i；图1常见6种复合材料定量评价表1常见6种复合材料具体考量指标第2页共15页PP/AC RTMRI PP/OC WLPMProcessProcess Score (higher is better)8.74.86.78.72.36.7CleanlinessMessy 0 10 Clean975919Difficulty / Skill

20、LevelDifficult 0 10 Easy423427Secondary Ops, trimming etc.No Ops 0 10 More Ops1011010103Volatile releaseOpen Air 0 10 None1010101003Controlled cure cyclesNone 0 10 Controlled105510010Controlled resin contentNone 0 10 Controlled947918ResultsResults Score (higher is better)9.27.46.78.12.08.0Compaction

21、None 0 10 Best10556210Complexity of partNone 0 10 Best895648RepeatabilityNone 0 10 Best888729Void ContentHigh 0 10 Low997719Fiber Orientation ControlNone 0 10 Best10681015Resin RichnessHigh 0 10 Low925909Repeatable Mechanical PropertiesLow 0 10 High977919Controlled WeightLow 0 10 High108910210Porosi

22、tyHigh 0 10 Low9108729Core Co-CuringBad 0 10 Good101051052MaterialsMaterials Score (higher is better)1.66.26.41.68.63.0Consumable costHigh 0 10 Low3923710Minimum Order Quantity of materialsHigh 0 10 Low166191Room temp cure resin systemsLow 0 10 High05100100Cost of materialsHigh 0 10 Low368393Shelf l

23、ife of materialsLow 0 10 High156181ToolingTooling Score (higher is better)3.35.36.73.36.05.0All surfaces are tooledOne 0 10 Multiple5105527Tooling CostHigh 0 10 Low315371CTE issuesHigh 0 10 Low2510297Operation CostOperation Score (higher is better)2.03.36.73.06.04.3Facility CostHigh 0 10 Low226484Fa

24、cility DedicationHigh 0 10 Low169292Labor IntensityHigh 0 10 Low325317EquipmentEquipment Score (higher is better)0.34.78.33.79.70.7Equipment ExpenseHigh 0 10 Low148392Dedicated unique equipmentHigh 0 10 Low0078100Part limited to equipment sizeNone 0 10 High010100100Average Score (higher is better)4.

25、253-吻与彦包勺哧产%N刁PP/AC = Prepreg/Autoclavet RTM = Resin Transfer Molding, RI = Resin Infusion, PP/OC = Prepreg/Oven Cure, WL = Wet Layup, PM = Press Molding2. Prepreg/Autoclave (预浸料/高压釜)第3页共15页Prepreg/AutoclaveProcess10 -EquipmentOperationCostResultsMaterialsTooling电 磁纤维及其复合材料技术Results ：航空级2.1. 等级：中级技能

26、在质量方面，基于预浸料的结构件在高压釜中固化，使其具有特定的优势。该过程可以高度控 制，从而产生优异的结果。但主要挑战包括昂贵的材料、工具、运营本钱和设备。第4页共15页PREPREG/AUTOCLAVE第5页共15页ProcessProcess Score (higher is better)8.7CleanlinessMessy 0 10 Clean9Difficulty / Skill LevelDifficult 0 10 Easy4Secondary Ops, trimming etc.No Ops 0 10 More Ops10Volatile releaseOpen Air 0

27、10 None10Controlled cure cyclesNone 0 10 Controlled10Controlled resin contentNone 0 10 Controlled9ResultsResults Score (higher is better)9.2CompactionNone 0 10 Best10Complexity of partNone 0 10 Best8RepeatabilityNone 0 10 Best8Void ContentHigh 0 10 Low9Fiber Orientation ControlNone 0 10 Best10Resin

28、RichnessHigh 0 10 Low9Repeatable Mechanical PropertiesLow 0 10 High9Controlled WeightLow 0 10 High10PorosityHigh 0 10 Low9Core Co-CuringBad 0 10 Good10MaterialsMaterials Score (higher is better)1.6Consumable costHigh 0 10 Low3Minimum Order Quantity of materialsHigh 0 10 Low1Room temp cure resin syst

29、emsLow 0 10 High0Cost of materialsHigh 0 10 Low3Shelf life of materialsLow 0 10 High1ToolingTooling Score (higher is better)3.3All surfaces are tooledOne 0 10 Multiple5Tooling CostHigh 0 10 Low3CTE issuesHigh 0 10 Low2Operation CostOperation Score (higher is better)2.0Facility CostHigh 0 10 Low2Faci

30、lity DedicationHigh 0 10 Low1Labor IntensityHigh 0 10 Low3EquipmentEquipment Score (higher is better)0.3Equipment ExpenseHigh 0 10 Low1Dedicated unique equipmentHigh 0，1版戌纵巾工Part limited to equipment sizeNone 0A般端出一【小仔刁3. 2. Resin Transfer Molding （树脂传递模塑）Resin Transfer MoldingProcess 10EquipmentEqu

31、ipmentOperationCostResultsMaterialsTooling上碳纤维及其复合材科技方Results：优秀的装饰品3.1. 技能等级：高技能使用树脂传递模塑工艺制造的部件可以产生美丽的外观。但该过程确实需要高水平的技能，并 且所有外表都必须经过加工处理。优势之一是材料本钱较低。第6页共15页RESIN TRANSFER MOLDING第7页共15页ProcessProcess Score (higher is better)4.8CleanlinessMessy 0 10 Clean7Difficulty / Skill LevelDifficult 0 10 Easy2

32、Secondary Ops, trimming etc.No Ops 0 10 More Ops1Volatile releaseOpen Air 0 10 None10Controlled cure cyclesNone 0 10 Controlled5Controlled resin contentNone 0 10 Controlled4ResultsResults Score (higher is better)7.4CompactionNone 0 10 Best5Complexity of partNone 0 10 Best9RepeatabilityNone 0 10 Best

33、8Void ContentHigh 0 10 Low9Fiber Orientation ControlNone 0 10 Best6Resin RichnessHigh 0 10 Low2Repeatable Mechanical PropertiesLow 0 10 High7Controlled WeightLow 0 10 High8PorosityHigh 0 10 Low10Core Co-CuringBad 0 10 Good10MaterialsMaterials Score (higher is better)6.2Consumable costHigh 0 10 Low9M

34、inimum Order Quantity of materialsHigh 0 10 Low6Room temp cure resin systemsLow 0 10 High5Cost of materialsHigh 010 Low6Shelf life of materialsLow 0 v 10 High5ToolingTooling Score (higher is better)5.3All surfaces are tooledOne 0 10 Multiple10Tooling CostHigh 0 10 Low1CTE issuesHigh 0 10 Low5Operati

35、on CostOperation Score (higher is better)3.3Facility CostHigh 010 Low2Facility DedicationHigh 0 10 Low6Labor IntensityHigh 0 10 Low2EquipmentEquipment Score (higher is better)4.7Equipment ExpenseHigh 0 10 Low4Dedicated unique equipmentHigh。一；缪Part limited to equipment sizeNone，可邛”杼，i4. 1. 1. Resin I

36、nfusion （树脂灌注）Resin InfusionProcess10 -EquipmentOperationCostResultsMaterialsTooling电 磁纤维及其复合材料技术Results ：消费品等级4.1. 技能等级：中级技能使用树脂灌注制造部件将产生消费品级结果。如果有预算，这是一个很好的过程，因为入门成 本不高，树脂灌注不需要特殊的设施。第8页共15页RESIN INFUSION第9页共15页ProcessProcess Score (higher is better)6.7CleanlinessMessy 0 10 Clean5Difficulty / Skill

37、 LevelDifficult 0 10 Easy3Secondary Ops, trimming etc.No Ops 0 10 More Ops10Volatile releaseOpen Air 0 10 None10Controlled cure cyclesNone 0 10 Controlled5Controlled resin contentNone 0 10 Controlled7ResultsResults Score (higher is better)6.7CompactionNone 0 10 Best5Complexity of partNone 0 10 Best5

38、RepeatabilityNone 0 10 Best8Void ContentHigh 0 10 Low7Fiber Orientation ControlNone 0 10 Best8Resin RichnessHigh 0 10 Low5Repeatable Mechanical PropertiesLow 0 10 High7Controlled WeightLow 0 10 High9PorosityHigh 0 10 Low8Core Co-CuringBad 0 10 Good5MaterialsMaterials Score (higher is better)6.4Consumable costHigh 0v10 Low2Minimum Order Quantity of materialsHigh 0 10 Low6Room temp cure resin sys