Article(id=1148011769068512002, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298830442578865, articleNumber=null, orderNo=null, doi=10.7654/j.issn.2097-1974.20240312, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1644595200000, receivedDateStr=2022-02-12, revisedDate=1703174400000, revisedDateStr=2023-12-22, acceptedDate=null, acceptedDateStr=null, onlineDate=1751636934773, onlineDateStr=2025-07-04, pubDate=1719244800000, pubDateStr=2024-06-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1751636934773, onlineIssueDateStr=2025-07-04, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1751636934773, creator=13701087609, updateTime=1751636934773, updator=13701087609, issue=Issue{id=1149298830442578865, tenantId=1146029695717560320, journalId=1146119989267898375, year='2024', volume='47', issue='3', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1751943794116, creator=13701087609, updateTime=1754895897628, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1161680850048344508, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298830442578865, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1161680850048344509, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298830442578865, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=79, endPage=84, ext={EN=ArticleExt(id=1148011769278227222, articleId=1148011769068512002, tenantId=1146029695717560320, journalId=1146119989267898375, language=EN, title=Study on the Influence of Riveting Squeeze Force on the Interference of GFRP / Aluminum alloy Layers Connection with ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ Rivets, columnId=1154057567442559335, journalTitle=Missiles and Space Vehicles, columnName=Material and Manufacturing, runingTitle=null, highlight=null, articleAbstract=

In order to control the riveting interference and minimize the damage of GFRP composite caused by riveting, it is necessary to study the influence trend of riveting squeeze force on the interference of ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ rivet. The dynamic riveting process and the interference of the rivet have been simulated by ABAQUS on the effects of diameter of pre-drilled hole and riveting squeeze force of ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ aluminum alloy rivet on GFRP composite and aluminum alloy layers. On the basis of the simulation the experimental investigations are performed. The Interference test and metallographic analysis of the specimens are conducted. Results indicate that the interference of the same measurement location in the rivet increases with the increase of the riveting squeeze force and the interference with the same riveting squeeze force decreases through-the-thickness. ${\Phi4.2}\mathrm{\;{mm}}$ diameter of pre-drilled hole and ${18.3}\sim {18.7}\mathrm{{kN}}$ riveting squeeze force can achieve the optimum interference and the GFRP composite has no apparent injuries.

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为了精确控制玻璃纤维增强塑料(Glass Fiber Reinforced Plastic,GFRP)/铝合金叠层的铆接干涉量,降低GFRP材料因铆接产生的损伤,需要对压铆力对干涉量的影响趋势进行研究。对$2\mathrm{A}{10}$材料${\Phi 4}\mathrm{\;{mm}}$铆钉在连接GFRP/$2\mathrm{A}{12}$铝合金叠层的电动伺服压铆过程及不同压铆力和预制孔下的铆接干涉量进行了有限元仿真分析,根据仿真结果开展了不同压铆力的压铆试验,对钉杆不同位置的干涉量进行了测量并做了微观检测分析。结果表明,同一预制孔下同测量位置的干涉量随着压铆力的增加而增大,同压铆力下干涉量沿叠层厚度方向(铆钉头向锻头方向)呈现递减趋势;选择$\mathit{Φ}$4.2mm预制孔、18.3$\sim$18.7kN压铆力能够获得理想干涉量且GFRP复合材料无明显损伤。

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朱亚蓉(1986-),女,高级工程师,主要研究方向为运载火箭箭体结构制造与质量检测技术。

马兴海(1981—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术、自动钻铆技术、数字化装配技术、先进连接技术等。

杨帅(1987—),男,工程师,主要研究方向为运载火箭箭体结构铆接装配技术、工业工程与工艺布局。

吴赞(1990—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术。

安立辉(1970—),男,博士,研究员,主要研究方向为运载火箭箭体结构制造技术、工艺管理。

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朱亚蓉(1986-),女,高级工程师,主要研究方向为运载火箭箭体结构制造与质量检测技术。

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朱亚蓉(1986-),女,高级工程师,主要研究方向为运载火箭箭体结构制造与质量检测技术。

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马兴海(1981—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术、自动钻铆技术、数字化装配技术、先进连接技术等。

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马兴海(1981—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术、自动钻铆技术、数字化装配技术、先进连接技术等。

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杨帅(1987—),男,工程师,主要研究方向为运载火箭箭体结构铆接装配技术、工业工程与工艺布局。

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杨帅(1987—),男,工程师,主要研究方向为运载火箭箭体结构铆接装配技术、工业工程与工艺布局。

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吴赞(1990—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术。

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吴赞(1990—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术。

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安立辉(1970—),男,博士,研究员,主要研究方向为运载火箭箭体结构制造技术、工艺管理。

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安立辉(1970—),男,博士,研究员,主要研究方向为运载火箭箭体结构制造技术、工艺管理。

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Demand for glass fibers by growing FRP/composites industry in China[J]. Fiber Glass, 2010(5): 51-56., articleTitle=Demand for glass fibers by growing FRP/composites industry in China, refAbstract=null), Reference(id=1197273332673458519, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, doi=null, pmid=null, pmcid=null, year=2011, volume=null, issue=4, pageStart=133, pageEnd=135, url=null, language=null, rfNumber=[2], rfOrder=2, authorNames=金浩, 程寓, 高超, journalName=机械设计与制造, refType=null, unstructuredReference=金浩, 程寓, 高超, 等.玻璃钢复合材料叠层结构钻削试验研究[J]. 机械设计与制造, 2011(4): 133-135., articleTitle=玻璃钢复合材料叠层结构钻削试验研究, refAbstract=null), Reference(id=1197273333386490201, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, doi=null, pmid=null, pmcid=null, year=2011, volume=null, issue=4, pageStart=133, pageEnd=135, url=null, language=null, rfNumber=[2], rfOrder=3, authorNames=JIN Hao, CHENG Yu, GAO Chao, journalName=Machinery Design & Manufacture, refType=null, unstructuredReference=JIN Hao, CHENG Yu, GAO Chao, et al.An experimental study on drilling of sandwich structure of GFRP composites[J]. 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squeeze force, figureFileSmall=SehxgDUQhl0H52wmFVIJvg==, figureFileBig=F2MpFdoN/RpFmfNGmAJvUg==, tableContent=null), ArticleFig(id=1197273321038459199, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=CN, label=图16, caption=${19.5}\mathrm{{kN}}$试片玻璃钢纤维断裂情况, figureFileSmall=SehxgDUQhl0H52wmFVIJvg==, figureFileBig=F2MpFdoN/RpFmfNGmAJvUg==, tableContent=null), ArticleFig(id=1197273321692770625, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=EN, label=Tab. 1, caption=Mechanical properties of of 2A12-T4 and 2A10-T4, figureFileSmall=null, figureFileBig=null, tableContent=
材料弹性模量/MPa泊松比密度$/\left({\mathrm{{kg}}\cdot {\mathrm{m}}^{-3}}\right)$
2A12-T4717000.312796
2A10-T4690000.332796
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材料弹性模量/MPa泊松比密度$/\left({\mathrm{{kg}}\cdot {\mathrm{m}}^{-3}}\right)$
2A12-T4717000.312796
2A10-T4690000.332796
), ArticleFig(id=1197273323399852357, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=EN, label=Tab. 2, caption=Mechanical properties of of GFRP, figureFileSmall=null, figureFileBig=null, tableContent=
弹性常数数值
${E}_{\mathrm{u}}$(纤维方向弹性模量)/MPa26000
${E}_{22}$(垂直纤维方向弹性模量)/MPa27200
${E}_{33}$(厚度方向弹性模量)/MPa8100
${G}_{12}$(面内剪切模量)/MPa4170
${G}_{13}= {G}_{23}$(垂直面内剪切模量)/MPa4170
${v}_{12}$(12方向波松比)0.13
${v}_{13}$(13方向波松比)0.13
${v}_{23}$(23方向波松比)0.13
${X}_{\mathrm{r}}$(纤维方向拉伸强度)/MPa602
$X\mathrm{c}$(纤维方向压缩强度)/MPa545
${Y}_{\mathrm{T}}$(垂直纤维方向拉伸强度)/MPa593
${Y}_{\mathrm{c}}$(垂直纤维方向压缩强度)/MPa472
${Z}_{\mathrm{T}}$(厚度方向拉伸强度)/MPa49.6
$Z\mathrm{c}$(厚度方向压缩强度)/MPa298
${S}_{12}$(面内剪切强度)/MPa70.3
${S}_{13}= {S}_{23}$(垂直面内剪切强度)/MPa67.4
), ArticleFig(id=1197273323869614407, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=CN, label=表2, caption=GFRP板材料性能数据, figureFileSmall=null, figureFileBig=null, tableContent=
弹性常数数值
${E}_{\mathrm{u}}$(纤维方向弹性模量)/MPa26000
${E}_{22}$(垂直纤维方向弹性模量)/MPa27200
${E}_{33}$(厚度方向弹性模量)/MPa8100
${G}_{12}$(面内剪切模量)/MPa4170
${G}_{13}= {G}_{23}$(垂直面内剪切模量)/MPa4170
${v}_{12}$(12方向波松比)0.13
${v}_{13}$(13方向波松比)0.13
${v}_{23}$(23方向波松比)0.13
${X}_{\mathrm{r}}$(纤维方向拉伸强度)/MPa602
$X\mathrm{c}$(纤维方向压缩强度)/MPa545
${Y}_{\mathrm{T}}$(垂直纤维方向拉伸强度)/MPa593
${Y}_{\mathrm{c}}$(垂直纤维方向压缩强度)/MPa472
${Z}_{\mathrm{T}}$(厚度方向拉伸强度)/MPa49.6
$Z\mathrm{c}$(厚度方向压缩强度)/MPa298
${S}_{12}$(面内剪切强度)/MPa70.3
${S}_{13}= {S}_{23}$(垂直面内剪切强度)/MPa67.4
), ArticleFig(id=1197273325048213833, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=EN, label=Tab. 3, caption=Interference of FEA model, figureFileSmall=null, figureFileBig=null, tableContent=
孔径/mm钉长/mm压铆力/kN干涉量/%
${I}_{1}$${I}_{2}$${I}_{3}$${I}_{4}$
4.111182.462.442.412.36
18.52.532.492.462.41
192.562.512.492.43
19.52.582.532.512.46
202.702.672.632.49
4.21117.91.871.831.771.70
18.31.931.881.811.75
18.71.961.921.831.78
19.12.001.951.881.82
19.52.051.991.921.85
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孔径/mm钉长/mm压铆力/kN干涉量/%
${I}_{1}$${I}_{2}$${I}_{3}$${I}_{4}$
4.111182.462.442.412.36
18.52.532.492.462.41
192.562.512.492.43
19.52.582.532.512.46
202.702.672.632.49
4.21117.91.871.831.771.70
18.31.931.881.811.75
18.71.961.921.831.78
19.12.001.951.881.82
19.52.051.991.921.85
), ArticleFig(id=1197273326168093004, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=EN, label=Tab. 4, caption=Riveting machine parameters, figureFileSmall=null, figureFileBig=null, tableContent=
最大压铆力/kN压铆行程/mm最大进给速度$/\left({\mathrm{{mm}}\cdot {\mathrm{s}}^{-1}}\right)$
55450250
), ArticleFig(id=1197273326285533518, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=CN, label=表4, caption=压铆机参数, figureFileSmall=null, figureFileBig=null, tableContent=
最大压铆力/kN压铆行程/mm最大进给速度$/\left({\mathrm{{mm}}\cdot {\mathrm{s}}^{-1}}\right)$
55450250
), ArticleFig(id=1197273328160387407, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=EN, label=Tab. 5, caption=Interference of riveting specimens, figureFileSmall=null, figureFileBig=null, tableContent=
孔径/mm钉长/mm压铆力/kN干涉量/%
${I}_{1}$${I}_{2}$${I}_{3}$${I}_{4}$
4.21117.92.182.142.101.98
18.32.232.192.132.05
18.72.282.222.172.10
19.12.312.232.202.14
19.52.352.282.232.17
), ArticleFig(id=1197273328886002001, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011769068512002, language=CN, label=表5, caption=铆接试片的干涉量, figureFileSmall=null, figureFileBig=null, tableContent=
孔径/mm钉长/mm压铆力/kN干涉量/%
${I}_{1}$${I}_{2}$${I}_{3}$${I}_{4}$
4.21117.92.182.142.101.98
18.32.232.192.132.05
18.72.282.222.172.10
19.12.312.232.202.14
19.52.352.282.232.17
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压铆力对${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$铆钉连接$\mathrm{{GFRP}}$/铝合金叠层的铆接干涉量影响研究
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朱亚蓉 1 , 马兴海 1, 2 , 杨帅 1 , 吴赟 1 , 安立辉 3
导弹与航天运载技术 | 材料与制造技术 2024,47(3): 79-84
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导弹与航天运载技术 | 材料与制造技术 2024, 47(3): 79-84
压铆力对${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$铆钉连接$\mathrm{{GFRP}}$/铝合金叠层的铆接干涉量影响研究
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朱亚蓉1, 马兴海1, 2, 杨帅1, 吴赟1, 安立辉3
作者信息
  • 1天津航天长征火箭制造有限公司,天津,300462
  • 2首都航天机械有限公司,北京,100076
  • 3中国运载火箭技术研究院,北京,100076
  • 朱亚蓉(1986-),女,高级工程师,主要研究方向为运载火箭箭体结构制造与质量检测技术。

    马兴海(1981—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术、自动钻铆技术、数字化装配技术、先进连接技术等。

    杨帅(1987—),男,工程师,主要研究方向为运载火箭箭体结构铆接装配技术、工业工程与工艺布局。

    吴赞(1990—),男,高级工程师,主要研究方向为运载火箭箭体结构铆接装配技术。

    安立辉(1970—),男,博士,研究员,主要研究方向为运载火箭箭体结构制造技术、工艺管理。

Study on the Influence of Riveting Squeeze Force on the Interference of GFRP / Aluminum alloy Layers Connection with ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ Rivets
Yarong ZHU1, Xinghai MA1, 2, Shuai YANG1, Yun WU1, Lihui AN3
Affiliations
  • 1Tianjin Long March Launch Vehicle Manufacturing Co. Ltd.,Tianjin,300462
  • 2Capital Aerospace Machinery Company Limited,Beijing,100076
  • 3China Academy of Launch Vehicle Technology,Beijing,100076
出版时间: 2024-06-25 doi: 10.7654/j.issn.2097-1974.20240312
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为了精确控制玻璃纤维增强塑料(Glass Fiber Reinforced Plastic,GFRP)/铝合金叠层的铆接干涉量,降低GFRP材料因铆接产生的损伤,需要对压铆力对干涉量的影响趋势进行研究。对$2\mathrm{A}{10}$材料${\Phi 4}\mathrm{\;{mm}}$铆钉在连接GFRP/$2\mathrm{A}{12}$铝合金叠层的电动伺服压铆过程及不同压铆力和预制孔下的铆接干涉量进行了有限元仿真分析,根据仿真结果开展了不同压铆力的压铆试验,对钉杆不同位置的干涉量进行了测量并做了微观检测分析。结果表明,同一预制孔下同测量位置的干涉量随着压铆力的增加而增大,同压铆力下干涉量沿叠层厚度方向(铆钉头向锻头方向)呈现递减趋势;选择$\mathit{Φ}$4.2mm预制孔、18.3$\sim$18.7kN压铆力能够获得理想干涉量且GFRP复合材料无明显损伤。

玻璃纤维增强塑料  /  压铆力  /  干涉量  /  递减趋势  /  理想干涉量

In order to control the riveting interference and minimize the damage of GFRP composite caused by riveting, it is necessary to study the influence trend of riveting squeeze force on the interference of ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ rivet. The dynamic riveting process and the interference of the rivet have been simulated by ABAQUS on the effects of diameter of pre-drilled hole and riveting squeeze force of ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ aluminum alloy rivet on GFRP composite and aluminum alloy layers. On the basis of the simulation the experimental investigations are performed. The Interference test and metallographic analysis of the specimens are conducted. Results indicate that the interference of the same measurement location in the rivet increases with the increase of the riveting squeeze force and the interference with the same riveting squeeze force decreases through-the-thickness. ${\Phi4.2}\mathrm{\;{mm}}$ diameter of pre-drilled hole and ${18.3}\sim {18.7}\mathrm{{kN}}$ riveting squeeze force can achieve the optimum interference and the GFRP composite has no apparent injuries.

glass fiber reinforced plastic  /  riveting squeeze force  /  interference  /  decrease  /  optimum interference
朱亚蓉, 马兴海, 杨帅, 吴赟, 安立辉. 压铆力对${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$铆钉连接$\mathrm{{GFRP}}$/铝合金叠层的铆接干涉量影响研究. 导弹与航天运载技术, 2024 , 47 (3) : 79 -84 . DOI: 10.7654/j.issn.2097-1974.20240312
Yarong ZHU, Xinghai MA, Shuai YANG, Yun WU, Lihui AN. Study on the Influence of Riveting Squeeze Force on the Interference of GFRP / Aluminum alloy Layers Connection with ${\Phi4}\mathrm{\;{mm}}2\mathrm{A}{10}$ Rivets[J]. Missiles and Space Vehicles, 2024 , 47 (3) : 79 -84 . DOI: 10.7654/j.issn.2097-1974.20240312
玻璃纤维增强塑料(Glass Fiber Reinforced Plastic, GFRP)具有比强度高、比硬度高、耐疲劳等优点,广泛应用于航空航天产品[1-4], GFRP材料在运载火箭箭体结构中主要用于壳段蒙皮、整流罩等产品。 GFRP材料构件一般通过铆接、螺接等方式与桁条、 环框等零件进行连接, 其中铆接工艺是运载火箭箭体结构中普遍采用的连接工艺。铆钉成型后钉杆从镦头到钉头方向呈现不同的膨胀量,对于含有复合材料的铆接结构而言容易导致复合材料的损伤破坏, 60%~ 80% 的复合材料连接结构破坏发生在连接处, 因此必须控制钉杆的膨胀[5-6],针对复合材料层板的最佳相对干涉量为${1.5}\%\sim 2\%{}$[7]
吕九九等[8]针对玻璃钢与铝合金叠层开展了$2\mathrm{A}{10\Phi 4}\mathrm{\;{mm}}\text{、}{\Phi 5}\mathrm{\;{mm}}$铆钉的液压压铆试验,两种规格铆钉分别在${8.5}\sim {10.5}\mathrm{{MPa}}$${11.5}\sim {14}\mathrm{{MPa}}$压铆力时铆钉的相对干涉量可控制在3%~4%。盛熙等[5]对碳纤维复合材料与铝合金叠层开展了${\Phi 3}\mathrm{\;{mm}}$${\Phi 3.5}\mathrm{\;{mm}}$${\Phi 4}\mathrm{{mm}}\mathrm{{TA}}1$铆钉电磁铆接研究,分别选用外径$7\mathrm{\;{mm}}$$8\mathrm{\;{mm}}$$9\mathrm{\;{mm}}$垫圈时可将干涉量控制在$2\%$以内,同时能够保证复合材料没有明显的损伤。张俊琪等[9]研究发现适当干涉配合能够提高复合材料连接结构的承载能力, 干涉量在1.5% 左右可以获得较高的承载能力。本文对2A10-T4材料${\Phi 4}\mathrm{\;{mm}}$铆钉在GFRP/ 2A12-T4叠层中的压铆过程及压铆力对铆钉干涉量影响趋势进行有限元仿真。在有限元仿真基础上开展了不同压铆力的电动伺服压铆试验, 对试验件的干涉量和金相进行了检测, 试验及检测结果验证了压铆力对相对干涉量影响趋势符合仿真结果, 并得出干涉量控制在2% 理想干涉量附近且GFRP复合材料无明显损伤的预制孔直径、压铆力等工艺参数。
GFRP/铝合金叠层:GFRP板为乙烯基酯树脂基玻璃纤维复合材料,厚度${2.8}\mathrm{\;{mm}}$; 铝板为$2\mathrm{\;A}{12}- \mathrm{T}4$铝合金材料,厚度$3\mathrm{\;{mm}}$;铆钉材料$2\mathrm{\;A}{10}- \mathrm{T}4$,直径${\Phi 4}\mathrm{\;{mm}}$,长度${11}\mathrm{\;{mm}}$。铆钉半圆头在GFRP板一侧, 镦头在2A12-T4板一侧,试片示意如图1所示。
2A12-T4板和2A10-T4铆钉的材料实测性能数据见表1, GFRP板的材料实测性能数据见表2; 2A12- T4板和2A10-T4铆钉实测的真实应力和塑性应变曲线分别见图2~3
运用ABAQUS仿真软件建立铆钉压铆成形的分析模型,模型包括铆钉、GFRP板、2A12-T4板、压铆头,按照表1~2图2~图3所列数据设置材料性能数据。采用$\mathrm{{C3D8R}}$单元类型按结构化网格技术形式对各零件进行网格划分, 网格划分模型如图4所示, 其中铆钉划分为176770个单元、GFRP板划分为217 728个单元、2A12-T4板划分为126720个单元、 压铆头划分为1600个单元。根据铆接实际情况建立6组接触, 如图5所示。6组接触分别为: ①铆模上端面为主面,铆钉下端和钉杆侧面为从面;②钉杆侧面为主面, GFRP材料板孔周为从面;③钉杆侧面为主面, 2A12材料板孔周为从面; ④铆钉半圆头下表面为主面, GFRP板上表面为从面;⑤钉杆侧面为主面,2A12板下表面为从面;⑥GFRP板和2A12板之间的接触面。
铆钉压铆过程分为整体自由镦粗和局部自由镦粗两个过程。初始阶段, 当压铆头和铆钉接触后, 由于钉杆与孔壁存在间隙, 铆钉杆首先发生整体镦粗变形, 随着压铆头的运动铆钉变形增加, 在钉杆变形最大处接触到孔壁材料。压铆力继续增加, 钉杆变形直至填满钉孔形成铆接干涉量。镦头处变形继续增加, 此时开始进入局部自由镦粗阶段,压铆力继续增加, 直至镦头形成。压铆变形的典型过程仿真结果如图6所示。通过对仿真结果进行分析, 当叠层预制孔分别为${\Phi 4.1}\mathrm{\;{mm}}\text{、}{\Phi 4.2}\mathrm{\;{mm}}$时,形成$\Phi \left({6 \pm {0.2}}\right)\mathrm{{mm}}$、高度$\left({2 \pm {0.2}}\right)\mathrm{{mm}}$铆钉镦头所需的压铆力范围分别为${18}\sim {20}\mathrm{{kN}}$${17.9}\sim {19.5}\mathrm{{kN}}$
$I$为相对干涉量、$D$为铆接后铆钉直径、$d$为铆接前铆钉孔直径,则相对干涉量可表示为式(1)。对铆接试件中的铆钉取4个位置分别进行干涉量测量, 测量位置示意如图7所示。
${I}_{i}= \left({{D}_{i}- d}\right)/d\left({i = 1,2,3,4}\right)$
${\Phi 4.1}\mathrm{\;{mm}}$${\Phi 4.2}\mathrm{\;{mm}}$预制孔径及不同压铆力对应仿真试件各测量位置的干涉量测量结果见表3, 干涉量对比见图8。由表3图8可以得出:a)预制孔为${\Phi 4.1}\mathrm{\;{mm}}$时,干涉量均超过了$2\%$,预制孔为${\Phi 4.2}\mathrm{\;{mm}}$时,干涉量在$2\%$附近; b)随着压铆力的增大, 相同预制孔下同测量位置的干涉量随之增大; c)同压铆力下铆钉不同位置的干涉量沿叠层厚度方向(铆镦头向镦头方向)呈递减趋势,即${I}_{1}> {I}_{2}> {I}_{3}> {I}_{4}$
根据仿真分析结果针对${2.8}\mathrm{\;{mm}}$乙烯基酯树脂基玻璃纤维复合材料GFRP板与$3\mathrm{\;{mm}}2\mathrm{\;A}{12}- \mathrm{T}4$板叠层伺服压铆$2\mathrm{\;A}{10}$材料${\Phi 4}\mathrm{\;{mm}}$铆钉时,${\Phi 4.1}\mathrm{\;{mm}}$预制孔、17.90~19.50 kN压铆力时干涉量普遍大于2%;${\Phi 4.2}\mathrm{\;{mm}}$预制孔、${17.90}\sim {19.50}\mathrm{{kN}}$压铆力时干涉量在理想干涉量2% 附近。同压铆力下预制孔大小不同时, 都表现出铆接干涉量沿叠层厚度方向(铆钉头向镦头方向)的递减趋势。
针对${2.8}\mathrm{\;{mm}}$GFRP与$3\mathrm{\;{mm}}$铝合金叠层,利用电动伺服压铆机(见图9, 设备主要参数见表4)对$2\mathrm{\;A}{10\Phi 4}\times {11}\mathrm{\;{mm}}$铆钉开展压铆试验,每组试片10件, 如图10所示。预制孔${\Phi 4.2}\mathrm{\;{mm}}$,压铆力分别设置为${17.90}\mathrm{{kN}}$${18.30}\mathrm{{kN}}$${18.70}\mathrm{{kN}}$${19.10}\mathrm{{kN}}$${19.50}\mathrm{{kN}}$。 试验后对试片进行干涉量检测和微观检测。
利用数控加工中心对试片进行逐层铣削, 加工至所需位置$\left({{D}_{1}\sim {D}_{4}}\right)$时,利用$\mathrm{{GE}}-5$型显微镜对试片进行拍照, 通过Digital viewer软件对铆钉直径进行测量(如图11所示), 计算铆钉相对干涉量。 10件试件同一位置的数据取平均值记为该位置的干涉量, 具体见表5,干涉量对比如图12所示。
可以得出:a)预制孔为${\Phi 4.2}\mathrm{\;{mm}}$时不同压铆力下各点干涉量稍大于2%;b)铆钉同测量位置的干涉量随压铆力增大而增大; c)同压铆力下铆钉不同位置干涉量沿叠层厚度方向(铆钉头向镦头方向)呈递减趋势,即${I}_{1}> {I}_{2}> {I}_{3}> {I}_{4}$。试验所得干涉量与压铆力的随变趋势与仿真结论一致。
为判断不同压铆力的压铆试片铆钉周围GFRP材料的损伤情况, 对试片进行微观检测, 检测位置如图13所示, 金相检测切取试样如图14所示。
${17.90}\mathrm{{kN}}$压铆力的铆接试片的微观分析如图15所示,由图15可以看出铆钉在$\mathrm{b}$$\mathrm{d}$$\mathrm{e}$区的方框所示位置存在局部轻微间隙。对比不同压铆力的试片可以得出随着压铆力逐步变大,间隙随之变轻微甚至没有间隙。${19.50}\mathrm{{kN}}$制备的试片GFRP纤维层缺陷如图16所示,其中在$\mathrm{d}$区方框位置出现了复合材料的脱粘现象, 具有由配合界面处向复合材料内部扩展趋势; f区方框内位置出现复合材料分层脱粘现象。对比不同压铆力的试片可以得出随着压铆力逐步变大,断裂情况呈加重趋势。压铆力为${18.30}\mathrm{\;{kN}}$${18.70}\mathrm{\;{kN}}$的试片介于两种内部缺陷之间, 铆钉钉杆与GFRP处无明显间隙,纤维损伤情况亦不明显。
本文对典型GFRP/铝合金叠层压铆工艺中压铆力对${\Phi 4}\mathrm{\;{mm}}2\mathrm{\;A}{10}$铆钉干涉量影响开展了有限元仿真及试验研究, 得出如下结论:
a)铆钉同测量位置的干涉量随压铆力增大而增大;
b)同压铆力下铆钉不同位置的干涉量沿叠层厚度方向(铆钉头向镦头方向)呈现递减趋势。
c)对常用的2A10材料${\Phi 4}\mathrm{\;{mm}}$铆钉铆接GFRP/铝合金叠层结构时,选择${\Phi 4.2}\mathrm{\;{mm}}$预制孔、${18.3}\sim$${18.7}\mathrm{{kN}}$压铆力能够将铆钉的干涉量控制在$2\%$理想干涉量附近且GFRP复合材料无明显损伤。
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2024年第47卷第3期
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doi: 10.7654/j.issn.2097-1974.20240312
  • 接收时间:2022-02-12
  • 首发时间:2025-07-04
  • 出版时间:2024-06-25
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  • 收稿日期:2022-02-12
  • 修回日期:2023-12-22
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    1天津航天长征火箭制造有限公司,天津,300462
    2首都航天机械有限公司,北京,100076
    3中国运载火箭技术研究院,北京,100076
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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