大型复合材料箱体成型模具设计

文 摘 为了制造合格的大型复合材料箱体，本文制定了箱体成型模具的设计和制造方案。某复合材料箱体属于大型长轴类产品，其成型模具挠曲变形及脱模力大。模具主体采用通长轴、周向辐板、轴向筋板和蒙皮组合的结构形式。模具通过无缝钢管、模具骨架及蒙皮形成的三维网状结构有效保证模具刚度，通过带斜度工作平面及变圆角设计大大降低脱模力，通过在顶出端使用更厚的钢板提升其在脱模时的可靠性。仿真结果表明，简支工况下模具最大应力值为42.9MPa，最大变形量为0.51mm；脱模工况下模具最大应力值为188.6MPa，最大变形量为0.5mm。根据模具结构制定了分别组焊、整体装配的加工工艺路线并完成了模具制造。仿真及模具实际使用结果表明，该模具满足复合材料箱体的生产需求。

Forming Mould Design of a Large-scale Composite Container

Abstract In order to manufacture eligible large-scale composite container, this paper formulates a design and manufacturing scheme for the forming mould of a composite container. The composite container is a large long-axis product, the foming mould of which would appear serious deflection and bear large demoulding force. The main mould structure adopts the combination structure of full-length steel pipe, web plates along circle direction, stiffeners along circle direction and skins. For the designed forming mould, the three-dimensional network structure made up by the seamless steel pipe, skeleton and skins effectively guarantees the rigidity; the draft surface and gradual fillet design significantly decreases the demoulding force; thicker steel plates were used in the ejection end to improve its reliability in the demoulding process. The simulation results show that the maximum stress value and deformation value are respectively 42.9MPa and 0.51mm in the simply supported condition, and the maximum stress values and deformation values are respectively 188.6MPa and 0.5mm in demoulding condition. According to the mould structure, the processing route of separately assembly welding and integrated assembling for the forming mould was formulated and the forming mould was manufactured. The simulation and practical use results show that the designed forming mould can meet the production needs of the large-scale composite container.