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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

叶红玲, 董永佳, 毛鹏琪, 肖扬, 解佳琳. 3D打印连续纤维复合材料工艺、结构优化研究进展. 力学进展, 2024, 54(2): 391-425 doi: 10.6052/1000-0992-23-048
引用本文: 叶红玲, 董永佳, 毛鹏琪, 肖扬, 解佳琳. 3D打印连续纤维复合材料工艺、结构优化研究进展. 力学进展, 2024, 54(2): 391-425 doi: 10.6052/1000-0992-23-048
Ye H L, Dong Y J, Mao P Q, Xiao Y, Xie J L. Research progress of process and structures optimization for 3D printed continuous fiber-reinforced polymers. Advances in Mechanics, 2024, 54(2): 391-425 doi: 10.6052/1000-0992-23-048
Citation: Ye H L, Dong Y J, Mao P Q, Xiao Y, Xie J L. Research progress of process and structures optimization for 3D printed continuous fiber-reinforced polymers. Advances in Mechanics, 2024, 54(2): 391-425 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
基金项目: 国家自然科学基金 (11872080), 北京市自然科学基金 (3192005) 资助项目
详细信息
    作者简介:

    叶红玲, 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

  • 中图分类号: O39

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

More Information
  • 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.

     

  • 图  1  3D打印连续纤维复合材料优化研究框图

    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)

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

    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)

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

    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)

    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)

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

    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)

    图  10  连续纤维路径规划研究 (Li N et al. 2020)

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

    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)

    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)

    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)

    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)

    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)

    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)

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

    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)

    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)

    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 14.1 250 —— (Oztan et al. 2019)
    CF Nylon 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 —— 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 43 272.51 299.36 (Ming et al. 2020a)
    Kevlar Nylon 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 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 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)
    下载: 导出CSV

    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
    密度/
    g/cm3
    线材直径/μm
    (单丝数, 直径)
    拉伸模量 /
    GPa
    弯曲模量 /
    GPa
    基体Nylon1.117500.940.84(Naranjo et al. 2019)
    PLA1.2517502.022.392(Chacón et al. 2017)
    ABS1.0417500.9981.9(Kabir et al. 2020)
    PEEK1.317503.73.6(Li W et al. 2020)
    Epoxy1.2517503.63.5(Kabir et al. 2020)
    连续纤维Carbon Fiber1.4400(1000, 10)5451(Dickson & Dowling 2019)
    Kevlar Fiber1.2300(1000,12)2726(Sugiyama et al. 2018)
    Glass Fiber1.5300(1000,10)2122(Dickson et al. 2017)
    下载: 导出CSV
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