机床用碳纤维增强树脂矿物复合材料的制备与性能研究
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摘要
近年来,我国在精密机床结构设计与运动控制等方面发展迅速,但大部分基础构件仍然采用铸铁或钢材焊接结构制成,制备周期较长,材料的减振特性已接近于极值,并且生产过程污染严重,研究开发具有优良阻尼性能的基础构件材料对于推动机械工业的技术进步具有重要的理论与工程实际意义。
树脂矿物复合材料以花岗石颗粒为骨料,以有机树脂作为粘结剂并选择添加部分增韧增强辅助组分制备而成,配合使用精密模具与预埋件设计工艺可在室温下一次浇铸成型,适用于制备精密机床的床身、底座等基础构件,其生产过程无需烧结,对环境基本无污染。
与铸铁相比,树脂矿物复合材料的阻尼减振性能优异,但强度较低,耐热膨胀性能较差,在一定程度上限制了其大量推广应用。本文提出添加碳纤维并配合骨料级配优化增强树脂矿物复合材料,在保证其原有高阻尼特性的基础上提高材料的强度与耐热膨胀性能为本文研究重点,主要研究内容包括：①树脂矿物复合材料的组分优选与制备工艺优化；②树脂矿物复合材料的分形骨料级配与纤维增强机理；③树脂矿物复合材料的能量损耗机理与阻尼表征；④树脂矿物复合材料的碳纤维阻胀机理与热膨胀性能；⑤树脂矿物复合材料精密车床床身结构优化。
基于树脂矿物复合材料的组分特征与反应机理优选树脂系统、骨料与辅助组分等,结合宏观特性表征获得各组分的基础配比范围。系统分析材料的长期性能变化规律,建立气泡的负压微圆柱模型,优化材料的制备与固化工艺,有效降低了树脂矿物复合材料的制备周期,材料七天强度达到149.92MPa。
通过统计分析与简化假设,综合考虑不同粒径骨料的分散堆积规律,结合颗粒填充理论确定最终的关键控制筛孔尺寸。基于分形理论获得更为精确的骨料级配配方与评价参量,配合颗粒流仿真与图像处理技术验证了堆积空隙率的变化趋势,仿真结果与实测值基本一致,可作为后续级配设计的预验证环节。建立骨料的微观应力传递模型,结合材料抗压强度测试结果验证了上述模型的合理性,结果表明,随着最大骨料粒径的增加,骨架强度升高,树脂用量减少,骨料颗粒内部的缺陷与微裂纹将对复合材料的强度产生一定的影响。基于剪滞理论系统研究碳纤维的应力传递机制,分别建立了纤维断裂与端部脱粘情况下的应力重新分布模型,结合纤维增强实验获得了碳纤维的最佳用量范围。
基于典型粘弹性材料的能量损耗机理获得树脂矿物复合材料的本征与界面阻尼表征因子,引入纤维方向效能系数定义,建立了树脂矿物复合材料的能量损耗机理模型。系统分析了树脂、骨料、增强纤维以及三者界面对应的材料阻尼产生机理,推导了微观界面滑移耗能公式,结果表明,增强纤维引入的大量界面将对树脂矿物复合材料阻尼性能产生重要影响。基于单因素实验获得了材料组分、骨料级配、纤维参量等对树脂矿物复合材料阻尼的影响规律,相比于其它因素,树脂的本征阻尼对树脂矿物复合材料的减振性能起主要作用,阻尼比最大值为目前常用HT200铸铁材料的十倍以上,合理的纤维用量与界面控制能够进一步提高材料的阻尼比,但需避免产生纤维缠绕结团现象。
基于碳纤维在中低温条件下的负热膨胀特点,建立了树脂矿物复合材料的碳纤维阻胀机理模型,升温过程中碳纤维受拉而复合材料受压,界面失配应力将对复合材料的受热膨胀产生一定限制。基于损伤力学研究了骨料-树脂、碳纤维-树脂界面的裂纹产生与扩展规律,对树脂矿物复合材料的受热破坏现象进行了合理解释。结合树脂的玻璃态温区范围选择80℃平均线热膨胀系数作为评定参量,实验研究了各因素对树脂矿物复合材料平均线热膨胀系数的影响定量表征,树脂矿物复合材料的最优热膨胀性能已达到9.627*10-6/℃。
应用Pro/E建立典型精密车床床身的简化三维模型并导入有限元分析软件,基于铸铁与树脂矿物复合材料的性能参量分别对模型进行了相应的定义。结合床身的实际工况分析并计算了静动态条件下的各部位受力情况,仿真分析了两种材料床身的静力学变形。在相同结构和尺寸条件下,树脂矿物复合材料床身在X、Y、Z方向的变形均为铸铁材料床身的3.5～3.6倍,提出了两种结构优化方案并进行了对应的静力学与热力耦合分析,优化后的树脂矿物复合复合材料床身变形能够满足整机刚度要求。优化设计的树脂矿物复合材料床身各阶固有频率均高于铸铁材料床身,一阶与二阶模态下的床身振型对导轨面的精度影响明显,在实际应用中需配合局部强化技术进行一定的增强。
For the past few years, structure design and motion control of precision machine tool in our country has developed rapidly, but most of the base components are still made of cast iron or steel welding structure, the preparation period is longer, vibration attenuation property is close to the limit and the environmental pollution in production process is serious. Research and development of materials with excellent damping performance has important theoretical and engineering practical significance in promoting technical progress of the engineering industry.
Resin mineral composite (RMC) is composed of granite aggregate, organic resin system and some other auxiliary components that it can be casting at room temperature in conjunction with precision mold and embedded part designing technology. RMC is suitable to produce the base components of precision machine tool, such as bed, base and so on. There is no high temperature sintering in its productive process, which is basically no pollution to the environment.
Compared with cast iron, RMC has better damping and vibration attenuation property. However, the strength of RMC is lower and the thermal expansion property is worse that its application is restricted to some extent, In this article, carbon fiber is used in cooperate with the gradation optimization of aggregate to reinforce RMC. How to improve the strength and thermal expansion performance on the basis of high damping property is the main research emphasis. The contents include the following:①Component and preparation optimization of RMC;②Fractal aggregate gradation and fiber reinforcing mechanism of RMC;③Energy loss mechanism and damping characterization of RMC;④Carbon fiber's block expansion mechanism and thermal expansion property of RMC;⑤Structure optimization of RMC precision lathe bed.
Based on the property of components and their reaction mechanism, resin system, aggregate and auxiliary components are optimized, the basic ratio of each component is obtained combined with the macroscopic characterization of RMC. Negative pressure cylinder model of bubble in RMC is established, the preparation and curing process is optimized according to the long-term behavior analysis, which can effectively reduce the preparation period. The compressive strength in the seventh day is already reached149.92MPa.
Statistical analysis and simplification are used, dispersion and stacking sequence of aggregates with different size are overall considered, the final dimension of screen holes are proposed based on the particle filling theory. Fractal theory is used to get a more accurate formula and gradation evaluation parameter. Particle flow simulation and image process method are used to identify the tendency of porosity, the simulation results are basically identical with the actually measured value that it can be used as a verification element in the follow-up gradation design. Stress transfer model of contiguous aggregates is established and compressive strength test is used to validate the aforementioned assumptions. Experimental results show that with the increase of the maximum aggregate size, skeleton strength increases and resin consumption reduced, internal defecs and micro cracks in single aggregate have more influence to the strength of RMC. Stress transmission mechanism of carbon fiber is systematically researched based on the shear lag theory, stress redistribution model under the fiber breakage or interface debonding condition are established respectively too, the optimal dosage of carbon fiber is acquired combined with the experimental research.
Effective intrinsic and interfacial damping factor is obtained based on the energy dissipation mechanism of viscoelastic materials, the fiber's direction coefficient is introduced and the model of energy loss mechanism is established. Mechanism of damping production between resin, aggregate, reinforcing fiber and their interfaces are analyzed detailedly, the energy dissipation formula of micro interface slip is deduced, which has important influence to the damping property. Single factor experiments are used to get the influence of component, aggregate gradation and fiber's parameter to the damping ratio. Compared to the other factors, intrinsic damping of resin plays the most important role in vibration attenuation. The maximum damping ratio is about ten times the HT200cast iron, reasonable fiber dosage and interface control can further improve the damping performance of RMC, but there also need to avoid the fibers'winding cluster phenomenon.
For the characteristic that carbon fibers have negative thermal expansion property in room temperature condition, its block-expansion model in RMC is established. In the warming process, carbon fiber is under tensile stress and RMC is under compressive stress, interface mismatch stress is generated, which can restrict the thermal expansion of RMC. The basic principle of damage mechanics is used to research the crack production and extension between aggregate, carbon fiber and resin, reasonable explanation is conducted to the destruction phenomenon under heat effect. Combined with the glass state temperature of resin, average thermal expansion coefficient in80℃is used as an evaluation parameter. Finally, the influence of each component is researched by experimental method, the optimal expansion coefficient of RMC is about9.627x10-6/℃.
Simplified three-dimensional model of typical precision lathe bed is established in Pro/E and imported into FEA software. The corresponding model definition is proceeded according to the parameter of cast iron and RMC. All the bed stress distribution under static and dynamic condition are analyzed and calculated according to their actual working conditions, their final deformations are acquired too. According to the results, the deformation of RMC precision machining tool in X, Y and Z direction are all about3.5～3.6times that of cast iron, two corresponding structure optimization schemes are proposed and the corresponding deformation analysis and thermal-mechanical analysis are conducted in order to satisfy the stiffness requirement of the machine tool. Natural frequency of optimized RMC in each order are all higher than cast iron, the first and second order have a more obvious influence to the guide rail surface, which needs to cooperate with local reinforcement technology in practical application.
树脂矿物复合材料以花岗石颗粒为骨料,以有机树脂作为粘结剂并选择添加部分增韧增强辅助组分制备而成,配合使用精密模具与预埋件设计工艺可在室温下一次浇铸成型,适用于制备精密机床的床身、底座等基础构件,其生产过程无需烧结,对环境基本无污染。
与铸铁相比,树脂矿物复合材料的阻尼减振性能优异,但强度较低,耐热膨胀性能较差,在一定程度上限制了其大量推广应用。本文提出添加碳纤维并配合骨料级配优化增强树脂矿物复合材料,在保证其原有高阻尼特性的基础上提高材料的强度与耐热膨胀性能为本文研究重点,主要研究内容包括：①树脂矿物复合材料的组分优选与制备工艺优化；②树脂矿物复合材料的分形骨料级配与纤维增强机理；③树脂矿物复合材料的能量损耗机理与阻尼表征；④树脂矿物复合材料的碳纤维阻胀机理与热膨胀性能；⑤树脂矿物复合材料精密车床床身结构优化。
基于树脂矿物复合材料的组分特征与反应机理优选树脂系统、骨料与辅助组分等,结合宏观特性表征获得各组分的基础配比范围。系统分析材料的长期性能变化规律,建立气泡的负压微圆柱模型,优化材料的制备与固化工艺,有效降低了树脂矿物复合材料的制备周期,材料七天强度达到149.92MPa。
通过统计分析与简化假设,综合考虑不同粒径骨料的分散堆积规律,结合颗粒填充理论确定最终的关键控制筛孔尺寸。基于分形理论获得更为精确的骨料级配配方与评价参量,配合颗粒流仿真与图像处理技术验证了堆积空隙率的变化趋势,仿真结果与实测值基本一致,可作为后续级配设计的预验证环节。建立骨料的微观应力传递模型,结合材料抗压强度测试结果验证了上述模型的合理性,结果表明,随着最大骨料粒径的增加,骨架强度升高,树脂用量减少,骨料颗粒内部的缺陷与微裂纹将对复合材料的强度产生一定的影响。基于剪滞理论系统研究碳纤维的应力传递机制,分别建立了纤维断裂与端部脱粘情况下的应力重新分布模型,结合纤维增强实验获得了碳纤维的最佳用量范围。
基于典型粘弹性材料的能量损耗机理获得树脂矿物复合材料的本征与界面阻尼表征因子,引入纤维方向效能系数定义,建立了树脂矿物复合材料的能量损耗机理模型。系统分析了树脂、骨料、增强纤维以及三者界面对应的材料阻尼产生机理,推导了微观界面滑移耗能公式,结果表明,增强纤维引入的大量界面将对树脂矿物复合材料阻尼性能产生重要影响。基于单因素实验获得了材料组分、骨料级配、纤维参量等对树脂矿物复合材料阻尼的影响规律,相比于其它因素,树脂的本征阻尼对树脂矿物复合材料的减振性能起主要作用,阻尼比最大值为目前常用HT200铸铁材料的十倍以上,合理的纤维用量与界面控制能够进一步提高材料的阻尼比,但需避免产生纤维缠绕结团现象。
基于碳纤维在中低温条件下的负热膨胀特点,建立了树脂矿物复合材料的碳纤维阻胀机理模型,升温过程中碳纤维受拉而复合材料受压,界面失配应力将对复合材料的受热膨胀产生一定限制。基于损伤力学研究了骨料-树脂、碳纤维-树脂界面的裂纹产生与扩展规律,对树脂矿物复合材料的受热破坏现象进行了合理解释。结合树脂的玻璃态温区范围选择80℃平均线热膨胀系数作为评定参量,实验研究了各因素对树脂矿物复合材料平均线热膨胀系数的影响定量表征,树脂矿物复合材料的最优热膨胀性能已达到9.627*10-6/℃。
应用Pro/E建立典型精密车床床身的简化三维模型并导入有限元分析软件,基于铸铁与树脂矿物复合材料的性能参量分别对模型进行了相应的定义。结合床身的实际工况分析并计算了静动态条件下的各部位受力情况,仿真分析了两种材料床身的静力学变形。在相同结构和尺寸条件下,树脂矿物复合材料床身在X、Y、Z方向的变形均为铸铁材料床身的3.5～3.6倍,提出了两种结构优化方案并进行了对应的静力学与热力耦合分析,优化后的树脂矿物复合复合材料床身变形能够满足整机刚度要求。优化设计的树脂矿物复合材料床身各阶固有频率均高于铸铁材料床身,一阶与二阶模态下的床身振型对导轨面的精度影响明显,在实际应用中需配合局部强化技术进行一定的增强。
For the past few years, structure design and motion control of precision machine tool in our country has developed rapidly, but most of the base components are still made of cast iron or steel welding structure, the preparation period is longer, vibration attenuation property is close to the limit and the environmental pollution in production process is serious. Research and development of materials with excellent damping performance has important theoretical and engineering practical significance in promoting technical progress of the engineering industry.
Resin mineral composite (RMC) is composed of granite aggregate, organic resin system and some other auxiliary components that it can be casting at room temperature in conjunction with precision mold and embedded part designing technology. RMC is suitable to produce the base components of precision machine tool, such as bed, base and so on. There is no high temperature sintering in its productive process, which is basically no pollution to the environment.
Compared with cast iron, RMC has better damping and vibration attenuation property. However, the strength of RMC is lower and the thermal expansion property is worse that its application is restricted to some extent, In this article, carbon fiber is used in cooperate with the gradation optimization of aggregate to reinforce RMC. How to improve the strength and thermal expansion performance on the basis of high damping property is the main research emphasis. The contents include the following:①Component and preparation optimization of RMC;②Fractal aggregate gradation and fiber reinforcing mechanism of RMC;③Energy loss mechanism and damping characterization of RMC;④Carbon fiber's block expansion mechanism and thermal expansion property of RMC;⑤Structure optimization of RMC precision lathe bed.
Based on the property of components and their reaction mechanism, resin system, aggregate and auxiliary components are optimized, the basic ratio of each component is obtained combined with the macroscopic characterization of RMC. Negative pressure cylinder model of bubble in RMC is established, the preparation and curing process is optimized according to the long-term behavior analysis, which can effectively reduce the preparation period. The compressive strength in the seventh day is already reached149.92MPa.
Statistical analysis and simplification are used, dispersion and stacking sequence of aggregates with different size are overall considered, the final dimension of screen holes are proposed based on the particle filling theory. Fractal theory is used to get a more accurate formula and gradation evaluation parameter. Particle flow simulation and image process method are used to identify the tendency of porosity, the simulation results are basically identical with the actually measured value that it can be used as a verification element in the follow-up gradation design. Stress transfer model of contiguous aggregates is established and compressive strength test is used to validate the aforementioned assumptions. Experimental results show that with the increase of the maximum aggregate size, skeleton strength increases and resin consumption reduced, internal defecs and micro cracks in single aggregate have more influence to the strength of RMC. Stress transmission mechanism of carbon fiber is systematically researched based on the shear lag theory, stress redistribution model under the fiber breakage or interface debonding condition are established respectively too, the optimal dosage of carbon fiber is acquired combined with the experimental research.
Effective intrinsic and interfacial damping factor is obtained based on the energy dissipation mechanism of viscoelastic materials, the fiber's direction coefficient is introduced and the model of energy loss mechanism is established. Mechanism of damping production between resin, aggregate, reinforcing fiber and their interfaces are analyzed detailedly, the energy dissipation formula of micro interface slip is deduced, which has important influence to the damping property. Single factor experiments are used to get the influence of component, aggregate gradation and fiber's parameter to the damping ratio. Compared to the other factors, intrinsic damping of resin plays the most important role in vibration attenuation. The maximum damping ratio is about ten times the HT200cast iron, reasonable fiber dosage and interface control can further improve the damping performance of RMC, but there also need to avoid the fibers'winding cluster phenomenon.
For the characteristic that carbon fibers have negative thermal expansion property in room temperature condition, its block-expansion model in RMC is established. In the warming process, carbon fiber is under tensile stress and RMC is under compressive stress, interface mismatch stress is generated, which can restrict the thermal expansion of RMC. The basic principle of damage mechanics is used to research the crack production and extension between aggregate, carbon fiber and resin, reasonable explanation is conducted to the destruction phenomenon under heat effect. Combined with the glass state temperature of resin, average thermal expansion coefficient in80℃is used as an evaluation parameter. Finally, the influence of each component is researched by experimental method, the optimal expansion coefficient of RMC is about9.627x10-6/℃.
Simplified three-dimensional model of typical precision lathe bed is established in Pro/E and imported into FEA software. The corresponding model definition is proceeded according to the parameter of cast iron and RMC. All the bed stress distribution under static and dynamic condition are analyzed and calculated according to their actual working conditions, their final deformations are acquired too. According to the results, the deformation of RMC precision machining tool in X, Y and Z direction are all about3.5～3.6times that of cast iron, two corresponding structure optimization schemes are proposed and the corresponding deformation analysis and thermal-mechanical analysis are conducted in order to satisfy the stiffness requirement of the machine tool. Natural frequency of optimized RMC in each order are all higher than cast iron, the first and second order have a more obvious influence to the guide rail surface, which needs to cooperate with local reinforcement technology in practical application.
引文
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