Disclosure of Invention
The invention aims to provide a method for monitoring the service process of a connecting structure of a composite material, which can monitor and identify the initiation, development and structural failure of the damage of the connecting structure of the composite material in real time.
To achieve the purpose, the invention adopts the following technical scheme:
The invention relates to a health monitoring method for a service process of a composite material laminated plate connecting structure, which comprises the following steps:
s1, selecting simulation software, establishing a finite element model of a composite material laminated plate connecting structure in the service process by using a numerical analysis method, acquiring an internal stress strain distribution cloud picture of the composite material laminated plate connecting structure, and taking a region with obvious and uniform stress strain change in the stress strain distribution cloud picture as an embedded position of an insulated sensor;
s2, uniformly coating insulating glue on the upper surface and the lower surface of the sensor connected with the signal transmission line respectively, and then curing the insulating glue on the upper surface and the lower surface of the sensor to form an insulated sensor;
S3, fixing the insulated sensor at the embedded position obtained by simulation in the step S1 in the process of paving the composite material laminated plate by adopting the prepreg laminated layers, curing the prepreg to form the composite material laminated plate assembled with the sensor, wherein the size of the composite material laminated plate assembled with the sensor is consistent with that of the composite material laminated plate in the composite material laminated plate connecting structure in the finite element model in the step S1;
S4, processing and assembling two composite material laminated plates into a connecting structure, wherein the connecting structure is consistent with the size of the finite element model in the step S1, and at least one composite material laminated plate in the two composite material laminated plates adopts a composite material laminated plate embedded with a sensor in the step S3;
and S5, connecting the sensor with a signal acquisition system, wherein the signal acquisition system is used for receiving the internal strain condition of the material output by the sensor, observing the acquired voltage signal, and indicating that the inside of the composite material connecting structure is damaged when the voltage signal is suddenly changed.
The invention has the beneficial effects that:
1. And the laying position is optimized, namely the sensor is embedded into the composite material, the common composite material is optimized into an intelligent material capable of realizing monitoring and feedback on damage, and the defects of low monitoring precision, poor monitoring effect and the like caused by the influence of environmental factors on the external sensor are avoided. The size of the material is not affected, and experiments prove that the mechanical properties of the composite material laminated plate embedded with the sensor are not reduced in the stretching and bending processes.
2. The sensor processing method in the laying process is optimized by processing the sensor by using the double-layer colloid, so that the fixation of a signal transmission line and the electric insulation of the sensor are respectively realized, and the phenomenon that the sensor is uneven and finally crushed in the preparation process of the composite material laminated plate when the data transmission line is connected by adopting a bonding wire method is avoided.
3. The operation is simple, no extra mould or other equipment is needed in the preparation process of the insulation sensor which can be embedded into the composite material, and the insulation sensor is matched with the preparation process of the composite material plate. The health monitoring of the connecting structure in the service process is realized without other sensors, and the inside damage of the composite material laminated plate is initiated on the premise of no shutdown inspection.
Detailed Description
The invention is described in further detail below with reference to the drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting thereof. It should be further noted that, for convenience of description, only some, but not all of the structures related to the present invention are shown in the drawings.
In the description of the present invention, unless explicitly stated or limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, and may, for example, be fixedly connected, detachably connected, or integrally formed, mechanically connected, electrically connected, directly connected, indirectly connected through an intervening medium, or in communication between two elements or in an interaction relationship between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
In the present invention, unless expressly stated or limited otherwise, a first feature "above" or "below" a second feature may include both the first and second features being in direct contact, as well as the first and second features not being in direct contact but being in contact with each other through additional features therebetween. Moreover, a first feature being "above," "over" and "on" a second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature is higher in level than the second feature. The first feature being "under", "below" and "beneath" the second feature includes the first feature being directly under and obliquely below the second feature, or simply means that the first feature is less level than the second feature.
In the description of the present embodiment, the terms "upper", "lower", "right", etc. orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are merely for convenience of description and simplicity of operation, and do not indicate or imply that the apparatus or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the invention. Furthermore, the terms "first," "second," and the like, are used merely for distinguishing between descriptions and not for distinguishing between them.
According to the method for monitoring the service process of the connecting structure of the composite material, the sensor is embedded into the material, so that the damage initiation, development and structural failure of the connecting structure of the composite material can be monitored and identified in real time. The process according to the invention is illustrated below by way of specific examples.
The invention relates to a health monitoring method for a service process of a composite material laminated plate connecting structure, which comprises the following steps:
S1, simulation software is selected, a finite element model of the composite material laminated plate connecting structure in the service process is established by utilizing a numerical analysis method, an internal stress strain distribution cloud chart of the composite material laminated plate connecting structure is obtained, and an area with obvious and uniform stress strain change in the stress strain distribution cloud chart is used as an embedded position of the sensor 1 after insulation.
Preferably, the material of the composite material laminated plate in the composite material laminated plate connecting structure is carbon fiber composite material or glass fiber composite material.
Preferably, the two borderlines of the insertion position are 20mm and 40mm, respectively, from the central axis of the connection piece 8 for connecting the composite laminate connection structure. The position stress strain distribution is uniform, and the acquisition of the stress strain change of the connecting structure can be realized on the basis of protecting the integrity of the sensor.
In the step, ABAQUS software is selected as simulation software, a finite element model of the composite material bolt connection structure in the service process is established by using a numerical analysis method, the finite element simulation method is widely applied, a stress-strain distribution cloud picture of the inside of the material can be obtained, and the stress condition of the sensor in the material can be judged. In other embodiments, the finite element model may be built by common commercially available finite element software. The composite connection structure may include various forms of bolting, riveting, glue-screw hybrid connection, and the like.
S2, uniformly coating insulating glue 3 on the upper surface and the lower surface of the sensor 1 connected with the signal transmission line 4 respectively, and then curing the insulating glue 3 on the upper surface and the lower surface of the sensor 1 to form an insulated sensor;
in this step, the sensor 1 to be mounted inside the composite material laminated plate 7 may be a piezoelectric ceramic sensor, and the monitoring effect may be better achieved by utilizing the advantages of small volume, sensitive piezoelectric effect and the like of the piezoelectric ceramic. In other embodiments, the sensor may also be selected from a piezoelectric fiber membrane sensor or a grating sensor.
And S3, fixing the insulated sensor 1 at the embedded position obtained by simulation in the step S1 in the process of paving the composite material laminated plate 7 by adopting the prepreg laminated layers, curing the prepreg to form the composite material laminated plate 7 assembled with the sensor, wherein the size of the composite material laminated plate 7 assembled with the sensor is consistent with that of the composite material laminated plate in the composite material laminated plate connecting structure in the finite element model in the step S1, and the upper surface and the lower surface of the sensor 1 coated with the insulating glue 3 are contact surfaces with the prepreg.
After the composite material laminated plate is cured, the laminated plate and the sensor form an intelligent material with the functions of identifying and feeding back damage.
And S4, processing and assembling two composite material laminated plates into a connecting structure, wherein the connecting structure is consistent with the size of the finite element model in the step S1, and at least one composite material laminated plate 7 of the two composite material laminated plates adopts a composite material laminated plate embedded with a sensor in the step S3.
And S5, connecting the sensor 1 with a signal acquisition system, wherein the signal acquisition system is used for receiving the internal strain condition of the material output by the sensor 1, observing the acquired voltage signal, and indicating that the inside of the composite material connecting structure is damaged when the voltage signal is suddenly changed.
Example 1
In the embodiment, the composite material prepreg is selected as a T700-grade carbon fiber unidirectional prepreg, and has the advantages of good dimensional stability, high specific strength, high specific modulus and the like.
And S1, in the step, ABAQUS software is selected as simulation software, a damage model is selected as a progressive damage model, and the progressive damage model is a common model in simulation analysis of the composite material, so that the evolution of the damage of the material is analyzed. In other embodiments, the reinforcing fiber material in the resin-based composite material may be selected, including carbon fibers, glass fibers, and the like, and corresponding damage models.
In this example, a single composite laminate 7 was selected having dimensions 189mm by 36mm by 2.5mm, the connector 8 was a phi 6mm size bolt, and the assembled simulation model is shown in FIG. 1, with the relevant dimensions in accordance with ASTM-D5961. The model provides two areas with fine grids, and the positions where PZT piezoelectric ceramics are expected to be embedded are subdivided by the grids, so that the conditions of stress and strain applied to the same positions between different layers can be judged. In other embodiments, the bolting configuration model dimensions may vary depending on the analysis targets.
In this embodiment, the simulation model may refer to the corresponding test standard with respect to the motion parameter setting during the experiment, and the model refers to the ASTM-D7264 standard in the tensile test and the ASTM-D5961 standard in the bending test. The simulation result can be obtained in the ABAQUS post-treatment stage, carbon fiber stress strain distribution cloud patterns of different layers in the service process are observed, and positions with uniform and obvious strain distribution are selected as embedding positions of the sensor.
In this embodiment, the sensor 1 is embedded in the middle layer of the composite material laminated plate 7, so that the sensor 1 can be ensured to have higher sensitivity to the damage of the connection structure under the condition of not being damaged. Meanwhile, according to the signal excitation mode of the piezoelectric ceramic sensor embedded in the composite material laminated plate 7, the transverse distance between the sensor and the connecting piece 8 is selected, namely, the sensor is located in the lap joint area of the two composite material laminated plates 7 and is far away from the connecting position. Preferably, the overlap area is determined in the present model to be 20-40mm from the attachment hole.
It will be appreciated that in other embodiments, the embedded position of the sensor may also be determined experimentally.
S2, respectively and uniformly coating insulating glue 3 on the upper surface and the lower surface of the sensor 1 connected with the signal transmission line 4, and then curing at high temperature
Upper and lower surfaces of the sensor 1;
In the step, the sensor inside the composite material laminated plate is a piezoelectric ceramic sensor, the diameter of a piezoelectric ceramic wafer is 7mm, and the thickness of the piezoelectric ceramic wafer is 0.2mm. The signal transmission line 4 is fixed at two ends of the piezoelectric ceramic wafer by using the fixing adhesive 2 to form a closed loop, so that a simple acquisition device is formed, and the structure of the simple acquisition device is shown in figure 2. The insulating glue 3 is uniformly coated on two sides of the acquisition device to insulate the surfaces of the acquisition device so as to adapt to weak conductivity in the carbon fiber composite material, and after high-temperature curing, the insulated sensor 1 which can be embedded in the composite material is obtained, and the structure of the insulated sensor is shown in figure 3. Preferably, the fixing adhesive 2 is a resin type pressure-sensitive adhesive, the cost of the resin type pressure-sensitive adhesive is low, the acquisition is easy, the fixing adhesive is still effective under the high temperature condition, the function of fixing a signal transmission line can be better achieved, and in other embodiments, the same or similar elastomer type pressure-sensitive adhesive can be used. The insulating glue 3 is one of high-temperature resin glue, and the high-temperature resin glue can be solidified after high temperature, so that the sensor can be insulated and protected from brittle damage. The insulating glue is j133 bi-component epoxy structural glue, and after being uniformly coated on two sides of the simple collecting device, the insulating glue is heated to 80 ℃ from room temperature in an insulation box at a speed of 3 ℃ per minute and is insulated for 180 minutes, so that the glue is solidified to complete insulation treatment. It can be understood that the sensor is insulated to ensure that the surface of the sensor is smooth, the internal piezoelectric ceramic wafer is free from cracks, and the signal transmission line is not broken.
And S3, fixing the insulated sensor 1 at the sensor embedding position in the process of paving the composite laminated plate 7 by adopting the prepreg overlapped layers, enabling the sensor to be positioned between the middle layers of the prepreg overlapped layers, and then curing the prepreg to form the composite laminated plate 7 assembled with the sensor 1, wherein the size of the composite laminated plate 7 assembled with the sensor is consistent with that of the composite laminated plate in the finite element model, and the upper surface and the lower surface of the sensor 1 coated with the insulating glue 3 are contact surfaces with the prepreg.
In this embodiment, the preparation process of the composite material laminated plate is as follows:
Firstly, the laying process of the composite material laminated plate selects standard orthogonal lamination sequence of resin-based carbon fiber composite materials widely used in the aviation field, and the size of the standard orthogonal lamination sequence is consistent with that of a simulation model. The final composite material laminated plate comprises 20T 700-level carbon fiber unidirectional prepregs with single-layer thickness of 0.125mm, wherein the prepregs 5 and 6 are alternately laid in the 0-degree fiber direction, and a sensor 1 is buried between the middle layers (10 layers and 11 layers) and is a piezoelectric ceramic sensor, and the structure of the sensor is shown in figure 4. The leading-out direction of the signal transmission line of the sensor is the same as the fiber direction of the prepreg layer, no crack in the sensor is ensured after the sensor is laid, and the insulating skin of the signal transmission line is not fallen.
Then, an autoclave molding method is selected as a preparation method of the fiber-reinforced thermosetting composite material, parameters such as curing pressure, temperature and the like of the autoclave are uniform and adjustable, and the molding process is stable and reliable, thus the method is a common preparation method of the composite material. The sample was cured in an autoclave, a standard mold was selected for preparing a thermoset composite material having a thickness of 2.5 mm. In the sample preparation process, the temperature in the autoclave is firstly heated from room temperature to 125 ℃, the speed is 1.5 ℃ per minute, the holding time is 2.5 hours, and finally the temperature is reduced at the speed of 3 ℃ per minute. During the whole cycle, a pressure of 3bar was applied, with an average vacuum of 98KPa. When the sample is placed in the autoclave, the signal transmission line and the plate are ensured to be placed flatly, and overlapping is not generated. In the sample curing process, the signal transmission line exposed outside the plate is wrapped by the plastic film, so that the resin is prevented from being heated to flow and adhere to the signal transmission line, and the transmission line is prevented from being damaged.
And S4, processing and assembling two composite material laminated plates into a connecting structure, wherein the connecting structure is consistent with the size of the finite element model in the step S1, and at least one composite material laminated plate 7 of the two composite material laminated plates adopts a composite material laminated plate embedded with a sensor in the step S3.
In this embodiment, a single lap bolt connection structure is taken as an example:
First, the composite laminate 7 is edge-milled and hole-punched by a numerical control machine. In the process of processing the sample by using the numerical control machine tool, the sample is ensured not to generate severe vibration. Three sides of the sample, from which the data transmission line is not led, are processed by a numerical control machine tool, and the plate size of the single composite material laminated plate is 189mm multiplied by 36mm multiplied by 2.5mm. And a through hole with the diameter of 6mm is manufactured at the position 18mm away from the narrow side of the composite material laminated plate by utilizing a numerical control machine tool so as to ensure that the embedded PZT sensor is positioned at the position 20-40mm away from the through hole, and the composite material laminated plate is prevented from layering damage at the sinking position of the sensor in the hole manufacturing process. Then, the two composite material laminated plates 7 are connected in series by using a connecting piece 8, such as a 12.9-level high-strength socket head cap screw, to form a single lap joint screw connecting structure, and the final structure is shown in fig. 5.
And S5, connecting the sensor 1 with a signal acquisition system, wherein the signal acquisition system is used for receiving the internal strain condition of the material output by the sensor 1, observing the acquired voltage signal, and representing that the inside of the composite material connecting structure is damaged when the voltage signal is suddenly changed.
In this embodiment, the sensor 1 is connected in series with the acquisition card, the signal amplifier and the computer, the lab view software is used to acquire the electrical signal generated by the sensor, and in the tensile experiment, the damage condition of the connection structure is judged by observing the change of the voltage signal amplitude, and when the voltage amplitude is suddenly changed, the damage occurs in the connection structure.
According to the method for monitoring the service process of the composite material connecting structure, provided by the embodiment, the sensor is embedded into the composite material to prepare the functional composite material with the function of collecting (monitoring) the internal damage in real time, so that the effect of monitoring the initiation and development process of the damage of the connecting structure in the service process in real time is achieved.
It is to be understood that the above examples of the present invention are provided for clarity of illustration only and are not limiting of the embodiments of the present invention. Various obvious changes, rearrangements and substitutions can be made by those skilled in the art without departing from the scope of the invention. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the invention are desired to be protected by the following claims.