虑及树脂分布非均匀性的一体化CFRP传动轴固化变形预测

doi:10.19936/j.cnki.2096-8000.20260928.005

摘要/Abstract

摘要： 大尺寸法兰-膜盘-轴管一体化碳纤维增强树脂基复合材料(Carbon Fiber Reinforced Polymer,CFRP)传动轴因其优异的比强度/刚度及减重潜力,已成为轻量化、高性能传动部件重要发展方向。针对现有模型尚难以准确描述树脂非均匀分布对一体化CFRP传动轴固化变形和残余应力影响的问题,提出一种虑及树脂分布非均匀性的一体化CFRP传动轴固化变形预测方法,通过建立不同树脂含量下的代表性体积单元(Representative Volume Element,RVE)模型,预测复合材料的力学性能、热膨胀及化学收缩特性,并将其映射至传动轴宏观有限元模型,模拟固化过程中的变形行为和应力分布。研究结果表明:一体化CFRP传动轴中树脂的非均匀分布显著影响变形和残余应力,传动轴上下两侧树脂体积分数差异每提升1%,最大固化变形增加0.63 mm,最大残余应力提升1.05 MPa;当复合材料上下两侧树脂体积分数差异达到40%时,轴管最大弯曲变形量可达23.67 mm(无膜盘)和22.45 mm(有膜盘),同时残余应力集中分布于一体化法兰与膜盘R角区域,最大应力增幅为102.4%。基于上述结论,进一步讨论了适用于工程实施的变形抑制策略,为高精度CFRP一体化传动轴的制造提供了重要的理论支撑和工艺优化途径。

关键词: CFRP传动轴, 一体化成型, 树脂非均匀, 固化变形, RVE建模, 性能预测

Abstract: Integrated carbon fiber reinforced polymer (CFRP) drive shafts featuring a flange-membrane disk-tube structure have emerged as a significant development direction for lightweight, high-performance transmission components, owing to their excellent specific strength/stiffness ratio and weight reduction potential. Addressing the unresolved challenge that existing models struggle to accurately characterize the influence of non-uniform resin distribution on cure-induced deformation and residual stresses within integrated CFRP drive shafts, this study proposes a novel cure deformation prediction method that incorporates resin distribution heterogeneity. Representative volume element (RVE) models with varying resin contents are established to predict the composite mechanical properties, thermal expansion, and chemical shrinkage characteristics. These predicted properties are then mapped onto a macroscopic finite element (FE) model of the drive shaft to simulate deformation behavior and stress distribution during the curing process. The research results demonstrate that non-uniform resin distribution significantly impacts deformation and residual stresses in integrated CFRP drive shafts. Specifically, for every 1% increase in the difference in resin volume fraction between the upper and lower sides of the shaft, the maximum cure-induced deformation increases by 0.63 mm, and the maximum residual stress rises by 1.05 MPa. Notably, when the resin volume fraction difference between the upper and lower composite sections reaches 40%, the maximum bending deformation of the tube section can reach 23.67 mm (without membrane disks) and 22.45 mm (with membrane disks). Concurrently, residual stresses are concentrated predominantly in the fillet regions of the integrated flange and membrane disk, exhibiting a maximum stress increase of 102.4%. Based on these findings, the paper further discusses deformation suppression strategies suitable for implementation in engineering. This work provides a crucial theoretical foundation and pathways for process optimization in the manufacturing of high-precision integrated CFRP drive shafts.

Key words: CFRP drive shaft, integrated molding, resin non-uniformity, curing deformation, RVE modeling, performance prediction

中图分类号:

TB332

聂慧阳, 周锦涛, 郭嘉炜, 龙俊米, 刘舒霆. 虑及树脂分布非均匀性的一体化CFRP传动轴固化变形预测[J]. 复合材料科学与工程, 2026, 0(9): 38-50.

NIE Huiyang, ZHOU Jintao, GUO Jiawei, LONG Junmi, LIU Shuting. Prediction of curing-induced distortion in integrated CFRP drive shafts considering non-uniform resin distribution[J]. COMPOSITES SCIENCE AND ENGINEERING, 2026, 0(9): 38-50.

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