COMPOSITES SCIENCE AND ENGINEERING

FAILURE ANALYSIS OF CARBON FIBER WINDED THIN-WALLED STEEL TUBE UNDER TRANSVERSE CRUSHING LOAD

SUN Jia-rui, MA Qi-hua, CAI Ming, HU Pei-yuan

2019, 0(9): 5-13.

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The bending collapse behavior of carbon fiber reinforced polymer (CFRP) wound steel circular hollow tubes was investigated under transverse quasi-static loading by three-point bending test and simulation. Five kinds of Steel/CFRP hybrid tubes with different winding layers or sequences were selected to analyze their bending failure process, failure modes and energy absorption characteristics. The results showed that the failure process of each hybrid tube under transverse loading was basically consistent with the pure steel tube, and the failure mode was dominated by the stable collapse mode of steel tube, while the failure morphologies were slightly different due to the influence of outer filament winding modes. On the energy absorption characteristics of hybrid tubes, it was found that the specific energy absorption of the hybrid tube increased with the increase of winding layers, and the distribution of (±45°) filament winding had a significant influence on the energy absorption characteristics of the hybrid tubes. Compared with the increase of the number of winding layers, reasonable winding sequences design can achieve better energy absorption performance. The special energy absorption of the Steel/CFRP [±45°/90°/90°]₂ hybrid tube is the best and 41.37% higher than that of the pure steel tube. On this basis, the Von-Mises stress distribution of composite laminates under different loads was analyzed by using the finite element model which is in good agreement with the experiment. It is proved that different winding angles have different effects on the stress burden, which provides a basis for improving the filament winding mode.

EFFECT OF BASALT FIBER PARAMETERS ON ASPHALT MIXTURE BASED ON SPATIAL DISTRIBUTION MODEL

YANG Cheng-cheng, LIU Zhao-hui, LIU Li, LI Sheng

2019, 0(9): 14-19.

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Aiming at the spatial distribution of basalt fibers in asphalt mixtures, the distribution model of basalt fibers in asphalt mixtures was established by using MATLAB, AutoCAD and ABAQUS. The effects of different spatial distribution of basalt fibers on the performance of asphalt mixtures were studied. Based on the spatial random distribution model, the effects of different fiber content and aspect ratio on the flexural-tensile properties of asphalt mixtures were analyzed. The results show that with the increase of fiber content and fiber aspect ratio, the maximum flexural stress of asphalt mixture layer bottom tends to decrease, that is, the better flexural-tensile performance of asphalt mixture. Considering the economy and actual construction conditions, the best effect of fiber reinforcement is obtained when fiber content is 0.3% and fiber aspect ratio is 35 (fiber length is 6 mm). The research results can provide a reference for the selection of reasonable basalt fiber content and aspect ratio in asphalt mixture.

SIMULATION METHODS FOR AXIAL CRUSHING CFRP TUBES IN LS-DYNA

HE Zhao-heng, LIU Ying, LI Neng-hua, LIU Qiang

2019, 0(9): 20-25.

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Carbon fiber reinforced plastic (CFRP) composite materials demonstrate significant promise to further improve weight to performance in automotive engineering. Nevertheless, parameters setting and modeling of CFRP component remains rather challenging in finite element method. In this prospective, this paper aims to promote the computational precision and efficiency of axial crushing CFRP tubes by establishing effective constitutive model that is implemented in commercial finite element package LS-DYNA. Three methods, including material parameters turning, modeling modification with different shell layers and different triggers were presented. First, experimental investigations have been conducted in order to obtain reliable MAT54 material parameters, and then the parameters without physical meanings was turned into reasonable range to improve correlation with experiments. Second, four numerical models with different shell layers were developed to simulate experimental crushing tests on the square CFRP tubes. Finally, the effect of triggers with different configuration for single shell layer model and double shell layers model were analyzed. The comparisons of numerical results with experimental data indicated that the double shell layers model with 45° trigger is capable of reproducing experimental results with relatively higher accuracy, which yielded up to only 2.55% error in terms of energy absorption. The simulation models and modeling methods in this paper are of guiding significance for analyzing CFRP tubes in LS-DYNA.

ANALYSIS OF MECHANICAL CHARACTERISTICS OF ARCHED FRP SAND-SAND STRUCTURE UNDER LOAD

WANG Qing-zhou, JIAO Cheng-yu, ZHOU Jian-bin, LUAN Hai-min

2019, 0(9): 26-31.

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In order to study the stress and deformation characteristics of the buried arched FRP sand-filled structure as the top of the assembled culvert, the arched FRP sand-filled structure is embedded in the concrete straight wall on both sides, and the maximum allowable deformation of the structure is taken as the control index. The simulated load test of the buried glass fiber reinforced plastic arched structure is carried out. The mechanical parameters of the arched structure under six working conditions, such as semicircle, semi-ellipse, load value and soil height, are studied. The feasibility of the glass-reinforced sand-sand structure as the top structure of the culvert is verified. The results show that in the case of the same deformation, the semi-elliptical arch structure with a cover height of 30 cm is 10.7% higher than the semicircle, 10.5% when the cover height is 60 cm, and 90 cm when the cover height is loaded to 52 tons. The shear failure of the body caused the test to terminate prematurely, and the FRP material did not show cracks and other damages; as the span ratio decreased, the horizontal thrust became larger. Under the same load, the semi-circular FRP sand-sand structure was covered in different soils. The horizontal and vertical displacements are 23%~33% and 16%~22% larger than the semi-ellipse, respectively. Therefore, the semi-elliptical structure is better stressed. Both arched FRP sand structures can be used as the assembled culvert top structure. This provides theoretical and technical support for the promotion and practical construction of FRP materials in the future.

FORECASTING METHOD OF THERMAL RESPONSE FOR FLAME RETARDANT MODIFIED GLASS FIBER EPOXY RESIN

FENG Zhen-yu, FAN Mao-hua, FAN Bao-xin, WANG Na-si-dan

2019, 0(9): 32-37.

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In order to study the thermal response of flame-retardant modified glass fiber epoxy resin composites in fire, considering the pyrolysis process in fire, the thermal response equations were established, and a finite difference method was used to calculate and analyze the material′s internal time-dependent temperature progressions and carbonization subjected to one-sided heat flux. The theoretical results from the established nonlinear thermal response equations were validated against experimental data and a good agreement is observed. Flame retardant modified glass fiber epoxy resin under the same heat flow conditions, the internal temperature of the material is slightly lower than the unmodified material. With the increment of the depth, the time flame retardant modified glass fiber epoxy resin reaching the pyrolysis temperature increases and the carbonization process slows down. The residual mass fraction of materials at different depth in the pyrolysis reaction zone is slightly different at the same temperature, the residual mass fraction decreases and the degree of carbonization increases as the deeper the position rose.

INFLUENCE ON BOLTS OF WIND TURBINE BLADE ROOT BUSHING CONNECTION BY CONNECTION PARAMETERS

BAI Hui-chao, SU Shao-chang, ZHANG Wen-wei, DENG Hang

2019, 0(9): 38-43.

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The influence of typical parameters to the strength of bushing connection bolts is analyzed, such as the thickness of flange, pretension force, the shaft diameter of bolt, and the initial thread depth of bushing. The results show that: ①The ultimate bearing capacity of the connection bolt can be increased by reducing the pretension force, increasing the thickness of flange, increasing the shaft diameter of the bolt, and reducing the initial thread depth of bushing; ②The fatigue life of connection bolt can be increased by increasing the pretension force, increasing the thickness of the flange and reducing the shaft diameter of bolts. Compared with the three parameters above, increasing the initial thread depth of the busing has the least influence on the fatigue life of the connection bolt.

INTERNAL FORCE DISTRIBUTION CALCULATION AND EXPERIMENT FOR BONDED-BOLTED HYBRID JOINTS OF COMPOSITE STRUCTURE

WU Cun-li, WAN Chun-hua, GUO Yu-chao

2019, 0(9): 44-51.

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Aiming at bonded-bolted hybrid joints of composite structure, internal force distribution calculation for joints is investigated. A new method is proposed based on loading-deformation curves of a typical hybrid joint. First, the loading-deformation for the typical hybrid joint is obtained by numerical simulation. Then, based on the loading-deformation curve, the strain distributions for the double row and five bolt single-lap composite joints are obtained by FEM. The analysis results are validated by test results. It shows that the strains obtained by FEM are in good agreement with the experimental data, which verifies that the method proposed in this paper is reliable. The method of this paper can be used to analyze the strength for other type of hybrid joints.

STUDY ON GALVANIC CORROSION BEHAVIOR BETWEEN CARBON/EPOXY COMPOSITES AND DIFFERENT METAL MATERIALS

GONG Wen-hua, DU Shu-jing, GAO Xiao-jin, JIANG Jian-ying

2019, 0(9): 52-57.

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The galvanic corrosion behavior between carbon/epoxy composites and 30CrMnSiA high-strength steel and 1Cr17Ni2 stainless steel were studied in this paper. Scanning electron microscopy (SEM) was used to observe the microscopic corrosion morphology of metal surface under different test conditions. Atomic energy spectrum analysis of 1Cr17Ni2 stainless steel samples were carried out. The results showed that, in direct contact, carbon/epoxy composite with 30CrMnSiA high-strength steel had obvious galvanic corrosion, but with 1Cr17Ni2 stainless steel it had almost no galvanic corrosion. The barrier effect of glass cloth/adhesive film on 30CrMnSiA high-strength steel was very obvious, which could significantly improve the corrosion resistance of 30CrMnSiA steel, but had little impact on 1Cr17Ni2 stainless steel. Carbon/epoxy composite and 30CrMnSiA high strength steel could only be used after protection, and 1Cr17Ni2 stainless steel could be used directly.

MECHANICAL BEHAVIOR OF FRP GRIDS AS TRANSVERSE REINFORCEMENT IN CONCRETE MEMBER

SHA Xiong, FENG Peng, YANG Jia-qi, WANG Ze-yuan

2019, 0(9): 58-63.

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Fibre-reinforced polymer (FRP) grids have the advantages of high-strength and anti-corrosion, and could be applied in concrete members as transverse reinforcements. Due to its linear elastic character and brittle failure modes, conventional material test methods are not able to capture the status and the failure modes of the grids in concrete structural members. In this work, two novel test methods, namely diagonal burst test and straight-line burst test, are proposed, with which failure modes and mechanical behaviour of FRP grids are obtained experimentally. Through the diagonal burst test, two typical failure modes, i.e. joint failure and rod failure,could be achieved. The strength of the joint can be tested to ensure the efficiency of grid rods in structural members. The straight-line burst test can obtain the strength efficiency when the grids fail in joint failure mode. According to the test results, a simplified strength model for FRP grids is proposed. The strength efficiency of FRP grids in square concrete columns subjected to axial compression is predicted with the proposed model. The predictions show good agreement with the test results.

EFFECT OF CARBON FIBER CONTENT ON PROPERTY OF REINFORCED NYLON COMPOSITE

CHEN Yi, HUANG Zhen-yuan, LIU Ying, LIU Qiang

2019, 0(9): 64-68.

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Carbon fiber can improve the mechanical properties of engineering plastics. This paper studies the effect of carbon fiber content on the properties and reinforced efficiency of carbon fiber reinforced nylon 66 (CF/PA66) composites, and analyzes the reasons for its enhancement. The CF/PA66 tensile specimens with fiber fraction of 10wt% to 40wt% were prepared by injection molding process. The elastic modulus and tensile strength of the reinforced composites were obtained through experiments and compared with the unreinforced samples. The effect of carbon fiber content on fiber-reinforced efficiency was analyzed. The fracture surface of tensile specimens was observed by scanning electron microscopy (SEM). The results show that the elastic modulus of CF/PA66 increases with the increase of fiber content, the tensile strength increases first and then decreases, and the peak value appears when the fiber content is 30wt%; the fiber-reinforced efficiency of CF/PA66 composites is not affected by carbon fiber content. The high fiber content of carbon fiber has lower tensile strength enhancement of CF/PA66 composites. The main reason is the weakening of micro-interface strength and the interface defect caused by the increase of fiber contact probability under high fiber content. The effect of the carbon fiber content studied on the reinforcing properties and efficiency of carbon fiber/PA66 materials can provide guidance for the design of reinforced composite materials.

EDDY CURRENT EFFECT OF IRON POWDER/EPOXY COMPOSITE AND ITS DEICING/ANTI ICING PERFORMANCE

QIN Wen-feng, FAN Yu-hang, WANG Xin-yuan, FU Jia-wei

2019, 0(9): 69-73.

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Iron/epoxy resin composites were prepared by adding micron-sized iron powder to epoxy resin matrix at room temperature. The microstructure and morphology of the samples were analyzed by scanning electron microscopy (SEM). Thermogravimetric analyzer (TGA) and infrared imager were used to analyze the thermal stability of the samples. The self-made electromagnetic heater is used to test the heating capacity and deicing capacity of the sample. Microstructure and morphology analysis showed that Fe powder particles were uniformly dispersed in the sample, and the particle size was between 0.5 um and 4 um. Thermal stability analysis showed that the mass loss of the sample was only 1% from 24 ℃ to 200 ℃, indicating good thermal stability. The results of electromagnetic induction experiment show that the content of Fe powder and the input power of the circuit affect the electrical conductivity and magnetic permeability of the sample and induce current to change induced EMF, and finally affect the surface temperature of the sample. The maximum average heating rate and deicing rate of Fe/Ep-100% samples were 1.1×10^-1 ℃/s and 1.2×10^-2 g/s, respectively.

LIGHTWEIGHT DESIGN AND VERIFICATION OF A CFRP LOWER CONTROL ARM

WEI Yuan-ping, YANG Qing, LIU Tao-ran, KANG Hua-ping

2019, 0(9): 74-78.

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Lightweight design for an aluminum lower control arm (LCA) is developed by using carbon sheet molding compound (C-SMC) and unidirectional prepreg tape (UD Tape) materials. Through the concept design and preliminary estimation, it is found that the optimization of fiber angel of UD tape during lay-up stacking can enhance the performance of structure along the main loading path strongly. Comparing to C-SMC and aluminum, anisotropic UD tape has more excellent mechanical property and design ability. Based on the UD Tape, we then developed the details of structure of LCA, and analysis the strength of the whole structure under the most dangerous load case and the strength of the joint between carbon fiber part and aluminum parts. Finally, we made a fatigue bench testing for LCA. The results show that CFRP LCA has remarkable lightweight effect, mechanical and anti-fatigue properties.

RESISTANCE PERFORMANCE OF KEVLAR/UHMWPE FIBER HYBRID COMPOSITES

XIAO Wen-ying, LI Xiang, GUO Wan-tao, MA Wu-wei

2019, 0(9): 79-84.

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The bulletproof property of Kevlar/UHMWPE fiber interlayer hybrid composites was studied. The composites with different strike face and hybrid ratio were theoretically analyzed by LS-DYNA. Also, process of bullet penetrating composites material is simulated, from which the stress and deformation process diagrams of composite materials are obtained. Moreover, the effect of hybrid ratio and strike face was studied by experiments, the fracture of the fibers was studied and the failure mechanism of the composites was further obtained. The results show that when aramid fibers work as strike face, resistance performance of hybrid composites is better. Furthermore, when the hybrid ratio is 1∶2, the resistance performance is the best.

RESEARCH ON STRESS CORROSION RESISTANCE OF CARBON FIBER COMPOSITES CORE OF ULTRA HIGH VOLTAGE TRANSMISSION CONDUCTOR

LAN Feng-tao, BAI Hui-tao, SUN Xiao-guang, ZHU Cheng-zhi

2019, 0(9): 85-88.

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Hybrid composite rods, comprised of unidirectional reinforcing carbon/glass-fiber and adhesive epoxy matrix, are regarded as promising candidates to be used in high-voltage overhead conductors. Before widespread application, their acid resistance needs to be clarified. But up to now, the study on this topic is still blank. In this study, Nitric acid resistance for hybrid composite rods, both epoxy resin castable and composites cores, is studied by immersing in 1 mol/L nitric acid for a long time. The sample come from different vendors are compared under the same conditions. The tensile strength of resin castable and tensile strength of cores are tested by electronic universal tester. It is found that the acid corrosion resistance of composites core depends on both the corrosion resistance of epoxy resin and the glass fiber specis. The epoxy resin exhibits different trends after 6000 h nitric acid immersing. E-CR glass fiber composites core have the better acid resistance than E glass fiber composites core. All above results can be used as experimental basis and selection criteria for carbon fiber composites core conductor overhead line design and operation.

PREPARATION AND PROPERTIES OF HYDROGENATED AEROGELS CATALYZED BY FLUORIDE ION AT NORMAL PRESSURE

YANG Zhen-yuan, ZHANG Yu-liang, LI Lei, LI Rong-xun

2019, 0(9): 89-92.

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At present, the commonly used aerogel gel process is acid-base catalysis, and the hydrolysis time is long and the operation process is cumbersome. In this paper, tetraethyl orthosilicate was used as the silicon source, and the wet gel was prepared by sol-gel method using fluoride ion as the catalyst. After the solvent was replaced by n-hexane solvent and the surface was modified by trimethylchlorosilane, the silica aerogel was prepared by stepwise heating at room temperature. Silica aerogels were studied by means of thermal conductivity analyzer, scanning/transmission electron microscopy and other methods to study the effect of different fluoride ion content on the properties of the prepared aerogels. Experiments show that the aerogel has a minimum density of 0.032 W/(m·K), an average specific surface area of 628.7 m²/g, and an average pore diameter of 17.2 nm. Moreover, with the increase of the amount of fluoride ion, the tetraethyl orthosilicate is more thoroughly hydrolyzed, but it is unfavorable for the surface modification of the wet gel, which leads to a smaller contact angle and an increase in thermal conductivity.

STUDY ON THE DESIGN OF A NEW TYPE OF COMPOSITE CROSSARM NODE IN THE MIDDLE PHASE OF A PORTAL CEMENT TOWER

ZHANG Wen-feng, CAO Ming-yang, LI Zhi-wei, ZHANG Jiang-peng

2019, 0(9): 93-99.

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For the composite transformation of 220 kV portal cement tower, we designed two types of nodes for connection of the middle phase composite crossarm. The first type of middle phase node is a "cat head type", which is divided into upper and lower parts, and the post insulators on both sides of the middle phase are consolidated by bolts. Meanwhile, a pair of boards are extended on both sides of the upper part of node, and connected to the line insulator to form a stable triangular structure composite crossarm. The second type of middle phase node is a "flange butt type", which is divided into three parts. First, specific flanges on both sides of node, and post insulator is integrally formed by glue. Second, a splint is arranged between the two special flanges. The splint not only provides the hanging point for the middle phase conductor, but also adjusts the distance between the cement rods on both sides of the door type cement pole tower. We used WorkBench to analyze the new composite crossarm node in the middle phase of the 220 kV portal cement tower, and obtained the stress distribution of each component. The analysis results show that the design of "flange butt type" node is reasonable and satisfy the stress requirements. Finally, we designed the electrical simulation and experiment for the "flange docking type" node and grading ring. The experimental results show that the mechanical and electrical performance of the "flange butt joint" node is stable and can meet the requirements of the engineering.

EFFECT OF SURFACE TREATMENT ON BOND STRENGTH OF THE BASE LAMINATE AND REPAIR PATCHES

XIONG Yu-cheng, BA De-ma, LI Chang-qing, CUI Hai-chao

2019, 0(9): 100-104.

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In the process of repairing composite materials, the bonding strength between the base laminate, the film and the patches is the main factor affecting the repairing effect. The surface treatment is often used to improve the bonding repair strength. In this paper, the composite material was ablated using a high-frequency pulsed ultraviolet laser, and the surface of the composite was polished with 38 μm (400 mesh) sandpaper followed by low temperature plasma treatment, and then the surface of the composite was polished again with 38 μm (400 mesh) sandpaper. The phase characteristics of the composite surface were analyzed by X-ray photoelectron spectroscopy. The tensile shear strength of the joint after surface treatment was tested by lap test. The shear failure mechanism of the lap joint was analyzed according to the experimental phenomenon. The results show that the shear strength of the specimen after laser treatment and sandpaper plus plasma treatment is higher than that of the specimen after sanding, which is increased by 17.9% and 10.9%, respectively. Laser ablation and plasma treatment can improve surface activity. The oxygen-containing functional group is increased, and the oxygen content is 2.2 times and 1.7 times that of the original surface, respectively.

EFFECT OF SEAWATER ON HYGROSCOPICITY AND MECHANICAL PROPERTIES OF PMI FOAM SANDWICH COMPOSITES

ZHENG Guo-dong, XU Xiao-ming, LEI Juan-juan, ZHANG Jing

2019, 0(9): 105-109.

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With the increasing use of foam sandwich composites in the marine industry, the impact of the marine environment on the performance of foam sandwich composites remains to be explored. In this paper, the mechanism of the influence of seawater on foam sandwich composites was investigated by comparing the difference in hygroscopicity and mechanical properties of PMI foam sandwich composites with deionized water and seawater. The test results show that the saturated moisture absorption rate of PMI foam sandwich composites immersed in seawater is 5.4%, and the time required for saturation is 28 days. The saturated water absorption rate and the time required for saturation of samples immersed in deionized water are 6.9% and 30 days, respectively. Through Fick′s second law of diffusion, the diffusion coefficient of water molecules in seawater is lower than that of water molecules in deionized water. In addition, the flat compressive strength, lateral compressive strength and flexural strength of the samples immersed in deionized water are decreased by 37.78%, 16.72%, and 23.71%, respectively, while the samples immersed in seawater are decreased by 35.56%, 21.2%, and 20.63%, respectively.

THE RESEARCH PROGRESS OF DYNAMIC CHARACTERISTICS OF THE COMPOSITE SANDWICH STRUCTURE

YANG Kun, ZHANG Wei, DU Du

2019, 0(9): 110-118.

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The composite sandwich structure is composed of upper and lower layer fiber reinforced composite and core layer, which has advantages of high specific strength, good damping property, design of fiber layer and light quality. It is often used as an vibration reducing structure. The study of its dynamic characteristics is instructive for its design. In this paper, the research achievements of dynamic characteristics of composite sandwich structure at home and abroad are reviewed, which include the mechanical analysis model of sandwich structure, core viscoelastic material constitutive model, the analysis method of the viscoelastic sandwich structure dynamic characteristic, viscoelastic composite sandwich beam and plate, discrete core composite sandwich structure. The calculation method of the dynamic characteristics of different structure and these limitations are summarized, and the breakthroughs and difficulties of different types of sandwich structure theory or numerical calculation are pointed out. Finally, the trend of future research on the dynamic characteristics of composite sandwich structures is also pointed out. It is concluded that, in the past, the structure damping properties prediction followed the course of gradually approaching the viscoelastic properties of materials, from regardless of frequency to frequency. The research object has the trend from the regular object to the large complex structure. In future, in terms of theoretical solution, the dynamic response closed solution of the sandwich beam and plate needs in-depth study. In terms of the dynamic response, the dynamic characteristics of the free paving layer surface structure need to be studied with the strip transfer function method. In application research, in order to reduce the scale and difficulty of calculation, a material constitutive model that can approximate the mechanical behavior and adapt to numerical solutions must be seeked, and accordingly improve the numerical solutions, will become a research hotspot.

RESEARCH PROGRESS OF PREFORMING OMEGA STRINGER OF COMPOSITE FUSELAGE

LIU Jun, HAN Xiao-yong, SU Jia-zhi, CHEN Ping

2019, 0(9): 119-123.

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Omega stringers are the key supportive components of composite fuselage panel, and the quality of stringer preform has everything to do with manufacturing of fuselage panel. Five processes (Hand lay-up/ATL+HDF/Automated roll forming/ATL+HPF/LCM) for manufacturing omega stringer preform are introduced, including the technical detail, advantage and disadvantage and application of each process. Finally, these processes are compared from mechanical effciency, productivity and overall cost to provide process proposals for manufacturing omega stringer preform.

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