3D打印连续纤维复合材料工艺、结构优化研究进展

叶红玲; 董永佳; 毛鹏琪; 肖扬; 解佳琳

doi:10.6052/1000-0992-23-048

3D打印连续纤维复合材料工艺、结构优化研究进展

doi: 10.6052/1000-0992-23-048

北京工业大学力学系, 北京 100124

基金项目: 国家自然科学基金资助项目 (11872080), 北京市自然科学基金资助项目 (3192005)

详细信息

作者简介:
叶红玲, 1972年出生, 北京工业大学数学统计学与力学学院教授, 工程力学国家级实验教学示范中心 (北京工业大学) 主任. 主要从事结构拓扑优化设计、智能复合材料、空间可展结构、计算力学理论方法等方面的研究, 在《Composite Structures》《Structural and Multidisciplinary Optimization》等期刊发表论文80余篇, 出版专著2部, 译著1部, 授权国家发明专利12项, 软件著作权60余项

通讯作者:
yehongl@bjut.edu.cn

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出版历程
- 收稿日期: 2023-11-14
- 录用日期: 2024-02-06
- 网络出版日期: 2024-02-19

Research progress of process and structures optimization for 3D printed continuous fiber-reinforced polymers

Department of Mechanics, Beijing University of Technology, Beijing 100124, China

More Information

Corresponding author: yehongl@bjut.edu.cn

摘要

摘要: 连续纤维增强复合材料由于优异的比强度、比刚度、可设计性和轻量化特质, 日益受到航空航天等高端装备制造领域的青睐. 3D打印技术的发展改变了连续纤维复合材料结构的生产制造流程, 使复杂结构的自由成型成为可能, 为先进结构材料提供了巨大的设计空间. 为充分发挥先进材料性能优势和3D打印成型灵活性, 研究人员分别从材料性能和结构设计出发, 探索与3D打印连续纤维复合材料相适应的设计制造一体化解决方案, 实现产品创新设计和性能提升. 本文系统性地回顾了面向连续纤维复合材料性能分析、工艺改进和结构优化的研究工作, 结合研究实践对连续纤维复合材料的结构多尺度优化方法进行总结分析, 并对未来先进材料结构设计实时化、功能化、智能化的发展趋势进行探讨和展望.
- 连续纤维复合材料 /
- 3D打印 /
- 力学性能 /
- 工艺优化 /
- 多尺度优化
Abstract: Continuous fiber-reinforced polymers (CFRP) has been broadly applied in the aerospace engineering due to its excellent specific strength, specific stiffness, designability and lightweight feature. The development of 3D printing has changed the manufacturing process of CFRP structures, which makes the free form of complex structures possible and provides more design space for advanced structural materials. In order to give full play to the performance advantages of CFRP and the flexibility of 3D printing process, and achieve innovative structural design and performance improvement, researchers explored the solutions of design and manufacturing integration for 3D printing CFRP from the aspects of material performance and structural design, respectively. In this paper, the development of properties analysis, process improvement and structure optimization of CFRP is reviewed systematically. Various multi-scale optimization methods of CFRP are summarized and illustrated, the development trend of real-time, functional and intelligent structural design method of advanced materials in the future is discussed and prospected.
- Continuous fiber-reinforced polymers /
- 3D printing /
- Mechanical properties /
- Process optimization /
- Multi-scale optimization

HTML全文

图 1 打印连续纤维复合材料优化研究框图

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图 2 连续纤维复合材料增材制造工艺. (a)材料挤出成型(Zhuo et al. 2021), (b)自动纤维铺放(Liu G et al. 2021), (c)分层实体制造(Chang et al. 2020)

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图 3 不同纤维体积分数对复合材料强度的影响(Goh et al. 2019)

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图 4 连续纤维复合材料单胞结构形状. (a)传统单胞形状(Sugiyama et al. 2018), (b)波纹夹层结构(Hou et al. 2018), (c)箭头型单胞(Gao Y et al. 2021), (d)金字塔型单胞(Liu S et al. 2018)

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图 5 连续纤维复合材料蜂窝夹层结构失效模式(Zeng et al. 2021b)

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图 6 不同打印温度的连续纤维复合材料界面和断裂模式. (a-c)180°C, (d-f)240°C (Tian et al. 2016)

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图 7 不同层高连续纤维复合材料界面和断裂模式. (a-c)层高0.5mm, (d-f)层高0.7mm (Tian et al. 2016)

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图 8 打印速度对弯曲强度和冲击强度的影响(Chen et al. 2021)

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图 9 纤维路径优化方法. (a)主应力方向(Sugiyama et al. 2020), (b)流线(Yamanaka et al. 2016), (c)应力梯度(Hou et al. 2021), (d)势流场(Khan et al. 2020)

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图 10 连续纤维路径规划研究 (Li et al. 2020)

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图 11 纤维路径优化方法的应用研究(Suzuki et al. 2020, Zhao et al. 2021)

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图 12 基于均匀化理论的连续纤维复合材料多尺度优化结果(Jung et al. 2022; Kim et al. 2020)

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图 13 基于离散纤维取向参数化的分步顺序多尺度拓扑优化策略(Lee et al. 2018)

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图 14 基于几何投影的纤维增强复合材料拓扑优化设计(Smith & Norato 2021)

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图 15 基于离散纤维取向参数化的多材料多尺度拓扑优化方法(Duan et al. 2023)

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图 16 连续纤维角度优化方法的二维(Luo et al. 2020)和三维应用(Schmidt et al. 2020)

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图 17 基于DCP的多打印平面纤维取向优化设计和制造流程(Qiu et al. 2022)

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图 18 基于主应力方向的连续纤维取向优化策略(Ye et al. 2023)

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图 19 基于PSO-CFAO法在不同初始纤维角度下的L型梁设计(Ye et al. 2023)

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图 20 连续纤维复合材料悬臂梁结构优化拓扑、纤维角度和最大Tsai-Wu值分布. (a)无约束设计, (b)残余应力约束设计(Dong et al. 2023)

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表 1 增材制造连续纤维复合材料力学性能汇总

工艺	纤维	基体	纤维方向	纤维体积分数 (%)	拉伸强度 (MPa)	弯曲强度 (MPa)	文献
ME	CF	Nylon	0°	14.1	250	——	(Oztan et al. 2019)
	CF	Nylon	0°	27	719	——	(Pyl et al. 2019)
	CF	Nylon	0°/90°	27	217	——	(Pyl et al. 2019)
	CF	Nylon	± 45°	27	48	——	(Pyl et al. 2019)
	CF	Nylon	0°/45°/90°	9.01	79	——	(Mei et al. 2019a)
	CF	Nylon	30°/45°/60°	9.28	69	——	(Mei et al. 2019a)
	CF	Nylon	Isotropic(0°)	30	534	——	(Chabaud et al. 2019)
	CF	Nylon	Isotropic(0°)	41	600	430	(Goh et al. 2018)
	CF	Nylon	Concentric	11	216	250.23	(Dickson et al. 2017)
	CF	Nylon	Concentric	40.97	300	——	(Al Abadi et al. 2018)
	CF	Nylon	Concentric	17.18	——	83.5	(Araya et al. 2018)
	CF	Nylon	Concentric	32.19	——	143.3	(Araya et al. 2018)
	CF	Nylon	Concentric	48.93	——	231.1	(Araya et al. 2018)
	CF	Epoxy	0°	——	792.8	202	(Hao et al. 2018)
	CF	PLA	——	20	26.57	60.14	(Yao et al. 2017)
	CF	PLA	Isotropic(0°)	34	91	156	(Li N et al. 2016)
	GF	Nylon	0°/90°	40.08	165	——	(Al Abadi et al. 2018)
	GF	Nylon	Isotropic(0°)	10	206	196.75	(Dickson et al. 2017)
	GF	Nylon	Isotropic(0°)	33.1	382	——	(Chabaud et al. 2019)
	GF	Nylon	Isotropic(0°)	35	450	149	(Goh et al. 2018)
	GF	Nylon	Concentric	8	194	165.79	(Dickson et al. 2017)
	GF	Epoxy	0°	43	272.51	299.36	(Ming et al. 2020a)
	Kevlar	Nylon	0°	16.5	150	——	(Oztan et al. 2019)
	Kevlar	Nylon	0°/90°	40.08	155	——	(Al Abadi et al. 2018)
	Kevlar	Nylon	Isotropic(0°)	10	164	125.8	(Dickson et al. 2017)
	Kevlar	Nylon	Concentric	8	150	106.6	(Dickson et al. 2017)
LOM	CF	Nylon	0°	49	1760.2	1025.9	(Chang et al. 2020a)
	CF	Nylon	0°/45°	49	1009.5	565.2	(Chang et al. 2020a)
	CF	Nylon	0°/90°	49	855.4	430.1	(Chang et al. 2020a)
	CF	PEEK	0°	59	1513.8	1901.1	(Chang et al. 2020b)
	CF	PEEK	0°/45°	59	782.8	1041.9	(Chang et al. 2020b)
	CF	PEEK	0°/90°	59	806.8	888.8	(Chang et al. 2020b)

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表 2 典型3D打印热塑性树脂和连续纤维增强复合材料的物理和力学性能

材料		材料特性				参考文献
材料		密度/ g/cm³	线材直径/μm (单丝数, 直径)	拉伸模量 / GPa	弯曲模量 / GPa	参考文献
基体	Nylon	1.1	1750	0.94	0.84	(Naranjo et al. 2019)
	PLA	1.25	1750	2.02	2.392	(Chacón et al. 2017)
	ABS	1.04	1750	0.998	1.9	(Kabir et al. 2020)
	PEEK	1.3	1750	3.7	3.6	(Li et al. 2020)
	Epoxy	1.25	1750	3.6	3.5	(Kabir et al. 2020)
连续纤维	Carbon Fiber	1.4	400(1000, 10)	54	51	(Dickson & Dowling 2019)
	Kevlar Fiber	1.2	300(1000,12)	27	26	(Sugiyama et al. 2018)
	Glass Fiber	1.5	300(1000,10)	21	22	(Dickson et al. 2017)

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