面向连续纤维增强聚合物复合材料熔融沉积成型的熔体流动仿真

连续纤维增强复合材料熔融沉积成型(CFRP-FDM)工艺因结合纤维复材轻质高强及增材制造设计高自由度优势而得到快速发展。为了增强CFRP-FDM打印机控形控性能力，以适应高速打印及频繁启停等需求，需要对其工艺过程机理与其结构设计有更深入的研究和理解。基于此背景，本课题面向聚合物及其预浸连续纤维增强复合材料FDM原位共挤出工艺的挤出过程，采用数值仿真方法，系统研究了聚合物熔体在挤出过程流动机理，并以此辅助热端流道几何尺寸优化设计，助力于打印性能和精度的提高。 首先，研究面向FDM挤出工艺，基于非等温粘弹性本构，构建了一个数值仿真模型。研究揭示了挤出过程中流道应力集中、弹性显著于粘性等基本粘弹性流动机理，并通实验验证了本模型在进给力预测的精确性，预测了进给力的超调滞后响应现象。此外，结合上述粘弹性研究基本结论，并基于非等温广义牛顿流体本构，对CFRP-FDM挤出工艺进行了仿真模拟。研究分析了压降分布、回流以及纤维受力等基本流动规律，得到了出口及相变界面应力集中、热端流道结构非对称性导致纤维丝偏移等粘弹流动推论。最后，本研究在数值仿真模型基础上，建立了基于代理模型的CFRP-FDM热端流道几何优化框架，最小化纤维受力、丝材进给力、停留时间等挤出头性能评价指标，获得了一系列最优的流道几何尺寸，并归纳了未来CFRP-FDM共挤出热端流道几何尺寸设计规律。 本研究对聚合物及其预浸连续纤维增强复合材料FDM工艺挤出过程进行了数值仿真建模，明晰了其工艺过程机理，优化了工艺参数控制及热端流道几何尺寸，为CFRP-FDM工艺的进步提供了基础。
 

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