CN108622123B - Low-cost carbon fiber composite air-iron vehicle body and manufacturing process - Google Patents
Low-cost carbon fiber composite air-iron vehicle body and manufacturing process Download PDFInfo
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- CN108622123B CN108622123B CN201810435802.3A CN201810435802A CN108622123B CN 108622123 B CN108622123 B CN 108622123B CN 201810435802 A CN201810435802 A CN 201810435802A CN 108622123 B CN108622123 B CN 108622123B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
- B61D17/06—End walls
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
- B61D17/08—Sides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
- B61D17/12—Roofs
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- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Body Structure For Vehicles (AREA)
- Laminated Bodies (AREA)
Abstract
The invention discloses a structure and a manufacturing process of a low-cost carbon fiber composite air-iron car body, belonging to the technical field of application of composite materials on rail vehicles, and comprising a car body side wall, wherein both ends of the car body side wall are respectively assembled and connected with end walls, the inner top surface and the inner bottom surface of the car body side wall are respectively assembled and connected with a top frame and an underframe, the outer top surface of the car body side wall is assembled and connected with a ceiling, and a bogie mounting hole is formed in the ceiling; the side wall and the end wall of the vehicle body both comprise reinforcing rib frameworks, inner skins and outer skins, and sandwich foam blocks are filled in grids of the reinforcing rib frameworks; the ceiling comprises a sandwich laminate, an upper skin and a lower skin; the top frame, the bottom frame, the reinforcing rib framework, the inner skin, the outer skin, the upper skin and the lower skin are all molded integrally by carbon fiber composite materials; the inside packing of strengthening rib skeleton has the core foam of pressing from both sides, reaches the function and the purpose of the structure that satisfy the mode of bearing of suspension type automobile body under the prerequisite of automobile body lightweight.
Description
Technical Field
The invention belongs to the technical field of application of composite materials on railway vehicles, particularly relates to the field of suspended air-iron, and particularly relates to a low-cost carbon fiber composite air-iron vehicle body and a manufacturing process thereof.
Background
At present, the research on carbon fiber composite car bodies in China is still in a starting stage, the composite materials in the current stage are only replaced in some non-stressed parts, the structural integration of the existing standard CFPR equipment cabin of the motor train unit is realized, the weight of the CFRP equipment cabin is reduced by 35% compared with that of an aluminum alloy structure, and a train adopting the standard CFPR equipment cabin of the motor train unit leaves the factory in 2015 in 6 months. A500 km/h high-speed test vehicle which is formed in 12 months in 2011 adopts a carbon fiber composite vehicle head cover. The cab of the Shanghai maglev train is the largest single-piece glass fiber reinforced locomotive in the world. At present, a composite material vehicle body for commercial operation does not exist in China.
The foreign research is relatively early, and the front end of the LRVCitidas train of Alston is molded by resin infusion; the DIAB company uses glass fiber composites to make the cab of a double-deck train; the FibrecomOy company of finland has developed a channel-type composite technology using honeycomb and foam core materials, applied to rail vehicle design; the TTX pendulum type train of the korean railway institute has a 23m long body shell, which is also the first train using a carbon fiber composite shell, and the body part (excluding the underframe) of the train is mainly made of a carbon fiber composite material, an aluminum honeycomb sandwich material and a stainless steel internal reinforcing frame, and the train has been put into commercial operation formally in 2010, and the weight of the train is reduced by 15% compared with the stainless steel shell, and the weight reduction effect is not obvious; ACS corporation also began to refer to composite body shells to produce a curved lightweight sandwich vehicle panel; the Talent train with a light mixed structure is produced by the company of Ponbdy, and a train body is made of a composite material; the Indian rail transit uses the composite material to design the gearbox, and the design of the composite material enables the weight of the gearbox to be reduced by 50%; the TVG high-speed train adopts the carbon fiber composite material to design the train body, and the weight of the train body is reduced by 25%; germany developed the first fiber composite truck in the world.
The carbon fiber composite material vehicle body in the prior rail train mainly has the following defects:
(1) in a strict sense, the middle framework of the currently developed carbon fiber composite material vehicle body adopts a full-welded aluminum alloy frame structure, and is not a full-carbon fiber composite material vehicle body, so that the problems of deformation mismatching and the like between a non-metal material and a metal material exist;
(2) the weight of the existing subway train body made of all carbon fiber composite material is not obvious, the cost is high, and the commercial operation is difficult;
in 2016, 9 and 10 days, the air train in the first line of China is formally offline, the high-capacity battery traction technology and the all-welded aluminum alloy frame structure and composite material skin technology are adopted, so that the light weight of the train body is realized, and the train body has the characteristics of attractive appearance, comfort, sound insulation, heat insulation and the like. In the future, the first world subway body made of the all-carbon fiber composite material and having completely independent intellectual property rights is developed, so that the whole subway body is reduced by about 35% compared with similar subway metal bodies, and the subway vehicle has great significance in improving the carrying capacity of the vehicle body, reducing energy consumption, reducing the whole life cycle cost, reducing line damage and the like.
The suspension type air-iron has enriched public transport systems, the pressure of other public transport is relieved, the most important of numerous advantages is that the overhead mode is adopted to fully utilize the ground space, just because of the characteristic of the suspension type air-iron, the suspension type air-iron train body has common characteristics with the train body of the traditional rail transport mode (light rail, subway and the like), higher requirements are provided for the light weight of the train body, because the suspension type air-iron has the advantages of good running environment, low cost, small load, low speed, small length and the like, the carbon fiber composite material of the suspension type air-iron train is the most ideal test train body, and other rail train bodies can be developed on the basis of the carbon fiber composite material train body of the air-iron train body. At present, a carbon fiber composite material car body for a suspended air-railway car is not available.
Due to the operating environment and the bearing mode of the subway train and the light rail train, the structure of the carbon fiber composite material train body of the suspension type air-rail train needs to be completely new in design and research and development at the present stage.
Disclosure of Invention
In order to solve the problems in the prior art, the invention aims to provide a low-cost carbon fiber composite material air-iron vehicle body and a manufacturing process so as to achieve the purpose of meeting the function and structure of a bearing mode of a suspension type vehicle body on the premise of light weight of the vehicle body.
The technical scheme adopted by the invention is as follows: a low-cost carbon fiber composite air-iron car body comprises a U-shaped groove-shaped car body side wall and a car bottom, wherein end walls are assembled and connected to two ends of the car body side wall; the inner top surface and the inner bottom surface of the side wall of the vehicle body are respectively assembled and connected with the top frame and the bottom frame; the outer top surface of the side wall of the vehicle body is assembled and connected with a ceiling matched with the end wall, and the ceiling is provided with a bogie mounting hole; the side wall and the end wall of the vehicle body both comprise latticed reinforcing rib frameworks, inner skins and outer skins, the inner skins and the outer skins are respectively attached to the inner side surfaces and the outer side surfaces of the reinforcing rib frameworks, and a plurality of sandwich foam blocks are filled in grids of the reinforcing rib frameworks; the ceiling comprises a sandwich layer plate, an upper skin and a lower skin, wherein the upper skin and the lower skin are respectively attached to the upper side surface and the lower side surface of the sandwich layer plate; the top frame, the bottom frame, the reinforcing rib framework, the inner skin, the outer skin, the upper skin and the lower skin are all molded integrally by carbon fiber composite materials; the reinforcing rib framework is of a hollow structure, and sandwich foam is filled in the reinforcing rib framework.
Furthermore, the sandwich foam blocks and the sandwich layer plate are all made of hard fireproof foam.
Furthermore, the cross section of the sandwich layer plate is in a trapezoid shape with an opening at the bottom edge, and an inner edge is arranged on the inner side wall of the opening; the inner edge is connected to the outer top surface of the side wall of the vehicle body through a screw.
Furthermore, the top frame comprises two transverse top edge beams, two longitudinal top edge beams and a top net frame, and the transverse top edge beams and the longitudinal top edge beams are in a U-shaped groove shape; the roof net rack is composed of an I-shaped roof beam and a rectangular roof longitudinal beam which are integrally formed, two ends of the I-shaped roof beam are respectively assembled into the two longitudinal roof side beams and are fixedly connected through bolts, and the end part of the rectangular roof longitudinal beam is assembled into the transverse roof side beam.
Further, the underframe comprises two transverse bottom edge beams, two longitudinal bottom edge beams, an I-shaped bearing beam and a bottom net rack, and the transverse bottom edge beams and the longitudinal bottom edge beams are in U-shaped groove shapes; the bottom net rack is composed of an I-shaped bottom cross beam and a rectangular bottom longitudinal beam which are integrally formed, two ends of the I-shaped bottom cross beam are respectively assembled into the two longitudinal bottom edge beams and are fixedly connected through bolts, and the end part of the rectangular bottom longitudinal beam is assembled into the transverse bottom edge beam; and two sides of the I-shaped bearing beam are respectively assembled and connected with the bottom net rack and the side wall of the vehicle body.
Furthermore, an embedded part positioned inside the sandwich foam block is embedded between the inner skin and the outer skin, and a threaded hole is reserved in the embedded part.
Furthermore, the outsides of the embedded part and the reinforcing rib framework are both coated with foaming layers.
The flange and the outward-protruding sliding groove are connected with the embedded part through bolts, and are connected with the surface of the inner skin in a bonding mode; and the inside of the flange is sleeved with a handrail.
The invention also discloses a manufacturing process of the low-cost carbon fiber composite air-iron car body, which comprises the following steps:
(1) manufacturing a mould: manufacturing a wood mold according to the cross section outline of the vehicle body, wherein the length of the vehicle body is a multiple of the length of the wood mold; laying a composite material layer on the surface of the wood mould by hand to form a composite material mould;
(2) ply and outer skin fabrication: sequentially paving a fiber composite material, a carbon fiber prepreg and a vacuum bag in the composite material mould in the step (1), and placing the composite material mould into an oven for curing to form an outer skin;
(3) placing a sandwich foam block and a reinforcing rib framework: paving a transition bonding layer on the inner surface of the outer skin in the step (2), placing a reinforcing rib framework on the transition bonding layer, placing sandwich foam blocks in grids of the reinforcing rib framework, adopting a secondary bonding process to bond and connect the sandwich foam blocks and the reinforcing rib framework with the outer skin, then placing the sandwich foam blocks and the reinforcing rib framework in an oven, vacuumizing and then carrying out integral curing;
(4) manufacturing a laying layer and an inner skin: sequentially paving a transition bonding layer, a carbon fiber prepreg and a fiber composite material on the cured surfaces of the sandwich foam blocks and the reinforcing rib frameworks in the step (3), bonding and connecting the sandwich foam blocks and the reinforcing rib frameworks with the carbon fiber prepreg by adopting a co-bonding process, placing the sandwich foam blocks and the reinforcing rib frameworks into an oven, vacuumizing and then performing overall curing to form a vehicle body unit;
(5) and (4) repeating the steps (1) to (4) to generate a plurality of vehicle body units, and forming the vehicle body by assembling and connecting the vehicle body units.
Further, the fiber composite material in the step (2) and the step (4) is glass fiber attached with metal mesh or aramid fiber attached with metal mesh; the composite material layering in the step (1) is made of glass epoxy resin matrix composite materials.
The invention has the beneficial effects that:
1. the invention adopts a mode of forming a double-bearing frame by matching the top frame and the bottom frame, is suitable for the operation mode of a suspended type air-rail vehicle body, and is different from the bearing structure mode of a subway vehicle; because the side wall and the ceiling of the car body are assembled and connected on the top frame, the top frame can bear the whole car body, the bogie passes through the bogie mounting hole to be connected with the top frame, the traditional mode that the roof of the car body is connected with the bogie is replaced, the underframe is connected in the side wall of the car body, the underframe is only used for bearing passengers, the load is transmitted to the side wall of the car body from the underframe and then to the top frame, the top frame directly bears the load through the bogie, and finally the load is transmitted to the upper surface of the track beam, so that the load is further distributed on the whole car body, and the maximization of the light weight of the;
2. the body of the carbon fiber composite air-iron vehicle body is of a carbon fiber composite sandwich structure and comprises an outer skin made of carbon fiber composite, an inner skin made of carbon fiber composite, a reinforcing rib framework made of carbon fiber composite and a sandwich foam block between the inner skin and the outer skin, and the integrated whole vehicle body is borne through a secondary bonding process and a co-bonding process; the integral rigidity of the car body is improved, a large number of parts and assembly work are reduced, the welding defect of metal is avoided, good sound and heat insulation effects are achieved, and the internal space of the car body is enlarged;
3. the side wall of the body of the carbon fiber composite air-iron vehicle body is of a sandwich structure formed by carbon fiber composite materials on two sides and a sandwich foam block positioned in the middle, the bending rigidity and the fatigue resistance of the vehicle body are greatly improved by the sandwich effect, and the fiber composite materials are laid on the surface of the carbon fiber composite materials and contain metal meshes, so that the impact resistance and the lightning protection performance of the vehicle body can be greatly improved;
4. the carbon fiber composite material air-iron vehicle body can also meet the functional design space of the connection between the bogie and the vehicle body, the placement of vehicle body equipment, the position of passengers, the placement of vehicle body tires and the escape function;
5. according to the invention, a plurality of vehicle body units are formed in a sub-module mode, and the vehicle body units are assembled and connected into the vehicle body, so that on one hand, compared with the traditional integrally formed vehicle body, strict requirements on the size of an autoclave or an oven can be avoided; on the other hand, a set of block dies can be suitable for various types of vehicle bodies, so that the cost is minimized;
6. according to the carbon fiber composite prepreg, the sandwich foam block and the sandwich layer plate are all made of hard fireproof foam, and the hard fireproof foam has the characteristics of flame retardance and no toxicity and environmental protection, so that the overall safety performance of a vehicle body is improved.
Drawings
FIG. 1 is a schematic overall structure diagram of a low-cost carbon fiber composite air-iron vehicle body provided by the invention;
FIG. 2 is an exploded view of a low-cost carbon fiber composite air-iron vehicle body according to the present invention;
FIG. 3 is a schematic cross-sectional view of a low-cost carbon fiber composite air-iron car body provided by the present invention;
FIG. 4 is a schematic structural diagram of a sandwich laminate in a low-cost carbon fiber composite air-iron car body provided by the invention;
FIG. 5 is a schematic structural diagram of a reinforcing rib framework in a low-cost carbon fiber composite air-railway vehicle body provided by the invention;
FIG. 6 is a schematic structural diagram of a top frame and a bottom frame of a low-cost carbon fiber composite material air-iron vehicle body provided by the invention;
FIG. 7 is a schematic view (I) of an assembly structure of a flange in a low-cost carbon fiber composite air-iron vehicle body provided by the invention;
FIG. 8 is a schematic view (II) of an assembly structure of a flange in a low-cost carbon fiber composite air-iron vehicle body provided by the invention;
FIG. 9 is a schematic view of an assembly structure of a low-cost carbon fiber composite material outward-protruding sliding groove in an air-railway vehicle body provided by the invention;
FIG. 10 is a schematic view of a first rigid connection mode in the manufacturing process of the low-cost carbon fiber composite air-iron vehicle body provided by the invention;
FIG. 11 is a schematic view of a rigid connection mode II in the manufacturing process of the low-cost carbon fiber composite material air-iron vehicle body provided by the invention;
FIG. 12 is a partial schematic view of a side wall of a vehicle body in the manufacturing process of the low-cost carbon fiber composite air-iron vehicle body provided by the invention.
Detailed Description
The invention is further described with reference to the following figures and specific embodiments.
As shown in fig. 1-9, the invention provides a low-cost carbon fiber composite air-iron vehicle body, which comprises a vehicle body side wall 4 in a U-shaped groove shape, wherein both ends of the vehicle body side wall 4 are respectively assembled and connected with an end wall 1, the end wall 1 is used for sealing both ends of the opening of the vehicle body side wall 4, the inner wall of the opening side of the vehicle body side wall 4 is provided with an inner edge, both sides of the inner edge are respectively an inner top surface of the vehicle body side wall 4 and an outer top surface of the vehicle body side wall 4, the inner top surface and the inner bottom surface of the vehicle body side wall 4 are respectively assembled and connected with a top frame 5 and an under frame 6, namely, the top frame 5 and the under frame 6 are both connected with the vehicle body side wall 4, the outer top surface of the vehicle body side wall 4 is assembled and connected with a ceiling 2 matched with the end wall 1, the length of the ceiling 2 is equal to the length of the vehicle body side wall 4 plus the thickness x2 of the end wall 1, a bogie mounting hole, the top frame 5 transfers the load to the suspension rails through the bogie; the side wall 4 and the end wall 1 of the vehicle body both comprise latticed reinforcing rib frameworks 7, inner skins 8 and outer skins 9, the inner skins 8 and the outer skins 9 are respectively attached to the inner side surfaces and the outer side surfaces of the reinforcing rib frameworks 7, the reinforcing rib frameworks 7 are used for improving the overall rigidity of the vehicle body, the integrity of the reinforcing rib frameworks 7 is ensured at the positions of doors or windows of the vehicle body, a plurality of sandwich foam blocks 10 are filled in grids of the reinforcing rib frameworks 7, and the sandwich foam blocks 10 are formed by cutting in advance and can be filled into the grids corresponding to the reinforcing rib frameworks 7; the ceiling 2 comprises a sandwich laminate 11, an upper skin 13 and a lower skin 12, wherein the upper skin 13 and the lower skin 12 are respectively attached to the upper side surface and the lower side surface of the sandwich laminate 11; the top frame 5, the bottom frame 6, the reinforcing rib framework 7, the inner skin 8, the outer skin 9, the upper skin 13 and the lower skin 12 are all molded integrally by carbon fiber composite materials, and the mechanical characteristics of the carbon fiber composite materials are utilized, so that the section rigidity of the vehicle body can be improved, and the overall weight of the vehicle body is reduced to the greatest extent; the reinforcing rib framework 7 is of a hollow structure, sandwich foam 15 is filled in the reinforcing rib framework 7, and the sandwich foam 15 is filled in the inner cavity of the reinforcing rib framework 7 through a foam mold, so that the reinforcing rib framework has the advantages of difficulty in demolding, large inertia moment and large attaching area; the automobile door and the automobile window have been seted up to the symmetry on the automobile body side wall 4, and strengthening rib skeleton 7 possesses the close-up design in the position department of automobile door and automobile window to guarantee strengthening rib skeleton 7's integrality.
Based on the structure:
possess the functional design of fleing: the suspended type air-iron vehicle body is arranged on the overhead and is about 8 meters away from the ground, passengers need to be transferred when the vehicle body has accidents such as fire and the like, and the vehicle body has an escape function and needs to be considered and designed. The escape equipment is mainly of an air bag type and a slide type, is placed under the bottom frame of the vehicle body, and once an accident occurs, passengers need to be transferred, and the escape equipment is automatically ejected out.
The design of the vehicle body moving function is provided: when the suspended air-iron vehicle body is placed on the ground or needs to move on the ground, tires need to be installed, the tires pop up when moving, and when the suspended air-iron vehicle body is suspended and runs, the tires are collected under the underframe.
The space between the ceiling and the top frame is mainly used for placing equipment such as an air conditioner, a power supply and the like of the vehicle body.
The sandwich foam 15, the sandwich foam block 10 and the sandwich layer plate 11 are all made of hard fireproof foam, wherein the sandwich foam block 10 and the sandwich layer plate 11 are produced into corresponding shape structures according to actual conditions, and the hard fireproof foam has the excellent characteristics of good heat insulation effect, light weight, high specific strength, convenience in construction and the like, and also has the characteristics of sound insulation, shock resistance, electric insulation, heat resistance, cold resistance, solvent resistance and the like.
The cross section of the sandwich layer plate 11 is in a trapezoid shape with an opening at the bottom edge, namely the sandwich layer plate 11 is in a trapezoid groove shape with an opening at one side surface, and an inner edge is arranged on the inner side wall of the opening; the inner edge is connected to the outer top surface of the side wall 4 of the car body through screws, so that the sandwich layer plate 11 is installed and fixed, and the roof 2 of the car body is installed.
The top frame 5 comprises two transverse top edge beams 16, two longitudinal top edge beams 17 and a top net rack, wherein the end parts of the two transverse top edge beams 16 and the two longitudinal top edge beams 17 are connected to form a rectangular frame structure, and the transverse top edge beams 16 and the longitudinal top edge beams 17 are both in a U-shaped groove shape; the roof net rack is composed of an I-shaped roof cross beam 19 and a rectangular roof longitudinal beam 18 which are integrally formed, two ends of the I-shaped roof cross beam 19 are respectively assembled into the two longitudinal roof side beams 17 and fixedly connected through bolts, the end part of the rectangular roof longitudinal beam 18 is assembled into the transverse roof side beam 16, preferably, the I-shaped roof cross beam 19 is uniformly arranged between the two transverse roof side beams 16, and the rectangular roof longitudinal beam 18 is uniformly arranged between the two longitudinal roof side beams 17.
The underframe 6 comprises two transverse bottom edge beams, two longitudinal bottom edge beams, an I-shaped bearing beam 14 and a bottom net frame, wherein the transverse bottom edge beams and the longitudinal bottom edge beams are in U-shaped groove shapes; the bottom net rack is composed of an I-shaped bottom cross beam and a rectangular bottom longitudinal beam which are integrally formed, two ends of the I-shaped bottom cross beam are respectively assembled into two longitudinal bottom edge beams, namely into grooves of the longitudinal bottom edge beams and fixedly connected through bolts, and the end part of the rectangular bottom longitudinal beam is assembled into a transverse bottom edge beam, namely the rectangular bottom longitudinal beam is assembled into grooves of the transverse bottom edge beam; the two sides of the i-shaped carrier bar 14 are respectively assembled and connected with the bottom net rack and the vehicle body side wall 4, preferably, the i-shaped bottom cross beams are uniformly arranged between two transverse bottom edge beams, and the rectangular bottom longitudinal beams are uniformly arranged between two longitudinal bottom edge beams.
An embedded part 20 positioned in the sandwich foam block 10 is embedded between the inner skin 8 and the outer skin 9, a threaded hole is reserved in the embedded part 20, and can be provided with a screw or a bolt, so that the purpose that the embedded part 20 can fix other facilities of the vehicle body is achieved, and preferably, the embedded part 20 is made of a titanium alloy material.
The embedded parts 20 and the reinforcing rib framework 7 are coated with foaming layers 21, and the foaming layers 21 can play a good role in heat insulation and buffering.
The outer skin is characterized by further comprising a flange 22 and an outer convex sliding groove 23, wherein the flange 22 and the outer convex sliding groove 23 are connected with the embedded part 20 through bolts, the flange 22 or the outer convex sliding groove 23 is fixedly installed by screwing the bolts, and the flange 22 and the outer convex sliding groove 23 are connected with the surface of the inner skin 8 in a bonding mode so as to further increase the installation stability of the flange 22 and the outer convex sliding groove 23; the flange 22 is sleeved with a handrail 24, and the flange 22 is used for fixing the handrail 24.
The invention also discloses a manufacturing process of the low-cost carbon fiber composite air-iron car body, which comprises the following steps:
(1) manufacturing a mould: manufacturing a wood mold according to the cross section outline of the vehicle body, wherein the length of the vehicle body is a multiple of the length of the wood mold; laying a composite material layer on the surface of the wood mould by hand to form a composite material mould; preferably, in the embodiment, the length of the vehicle body is set to 9 meters, and the length of the wood mold is set to 4.5 meters, the composite material laying layer integral forming technology can greatly reduce the number of parts, thereby reducing the weight of the structure and the manufacturing cost, and meanwhile, the number of fasteners is greatly reduced, thereby reducing the weight of the structure and the assembly cost of the structure.
(2) Lay-up and outer skin 9 fabrication: sequentially paving a fiber composite material 27, a carbon fiber prepreg 26 and a vacuum bag in the composite material mould in the step (1), sealing and applying surface pressure to the vacuum bag, and placing the vacuum bag into an oven for curing to form an outer skin 9;
(3) placing the sandwich foam block 10 and the reinforcing rib framework 7: paving a transition bonding layer 25 on the inner surface of the outer skin 9 in the step (2), placing a reinforcing rib framework 7 on the transition bonding layer 25, placing a sandwich foam block 10 in a grid of the reinforcing rib framework 7, bonding and connecting the sandwich foam block 10 and the reinforcing rib framework 7 with the outer skin 9 by adopting a secondary bonding process, bonding and connecting the sandwich foam block 10 and the reinforcing rib framework 7 with the outer skin 9 through the transition bonding layer 25, then placing the sandwich foam block 10 and the reinforcing rib framework 7 in an oven, vacuumizing and then integrally curing; (as shown in FIG. 12)
(4) Lay-up and inner skin 8 fabrication: sequentially paving a transition bonding layer 25, a carbon fiber prepreg 26 and a fiber composite material 27 on the cured surfaces of the sandwich foam block 10 and the reinforcing rib framework 7 in the step (3), bonding and connecting the sandwich foam block 10 and the reinforcing rib framework 7 with the carbon fiber prepreg 26 by adopting a co-bonding process, bonding and connecting the sandwich foam block 10, the reinforcing rib framework 7 and the carbon fiber prepreg 26 through the transition bonding layer 25, placing the sandwich foam block, the reinforcing rib framework 7 and the carbon fiber prepreg 26 into a drying oven, vacuumizing and then performing integral curing to form a vehicle body unit; (as shown in FIG. 12)
(5) And (4) repeating the steps (1) to (4) to generate a plurality of vehicle body units, forming a vehicle body by assembling and connecting the vehicle body units, and forming a rigid connection or a non-rigid connection between two adjacent vehicle body units.
Aiming at the step (1), a sub-module forming technology is adopted, and the specific steps are as follows: the length of the car body can be different according to different models, the cross-sectional shapes are similar, the cost is reduced to the maximum extent on the premise of integrated integral forming process and mould generalization, and the blocking mould has important significance.
The block mold is that the original mold of the car body is divided into two or more blocks, on one hand, the strict requirements on the size of the autoclave or the oven can not be carried out any more; on the other hand, one set of block die can be suitable for multiple models, and the lowest cost is realized.
When the car body is divided into several car body units and then connected into a whole through equipment, the result is usually no integrally formed rigidity, and the assembly connection part is the weakest link in the whole car body. In the embodiment, a connection mode between large sections is adopted to ensure the rigidity of an assembly connection part, and two modes of rigid connection and non-rigid connection are mainly adopted, wherein (1) the rigid connection mainly adopts a rigid connection mode between the vehicle body side walls 4 and is divided into connection of vehicle body units through bolts after butt joint or mutual sleeving of the vehicle body units; (2) the connection between the two vehicle body units is realized by adopting a non-rigid connection mode, namely, a sealed rubber windshield is adopted, so that the relative movement between the two vehicle body units is realized.
As shown in particular in figures 10 and 11,
as shown in fig. 10, when the body units are molded by a mold, the port positions of the body units are closed to form inner edges, and after two adjacent body units are butted, the inner edges are attached to each other and then are assembled and connected by bolts;
as shown in fig. 11, when the body units are molded by the mold, a sleeve opening is formed by closing up at a port position at one end of the body unit, and the size of the sleeve opening is slightly smaller than that of the port of the body unit, so that the two body units can be assembled in a manner of being sleeved with each other.
The fiber composite material 27 in the step (2) and the step (4) is glass fiber attached with a metal mesh or aramid fiber attached with a metal mesh, and the metal mesh can be attached to the surface of the glass fiber or the aramid fiber; the composite material layering in the step (1) is made of glass epoxy resin matrix composite materials.
The carbon fiber prepreg 26 may be a carbon fiber T700 prepreg or a carbon fiber epoxy one-way tape prepreg.
The invention is not limited to the above alternative embodiments, and any other various forms of products can be obtained by anyone in the light of the present invention, but any changes in shape or structure thereof, which fall within the scope of the present invention as defined in the claims, fall within the scope of the present invention.
Claims (8)
1. A low-cost carbon fiber composite air-iron car body is characterized by comprising a car body side wall in a U-shaped groove shape, wherein both ends of the car body side wall are respectively assembled and connected with an end wall, the inner top surface and the inner bottom surface of the car body side wall are respectively assembled and connected with a top frame and an underframe, the outer top surface of the car body side wall is assembled and connected with a ceiling matched with the end wall, and a bogie mounting hole is formed in the ceiling; the side wall and the end wall of the vehicle body both comprise latticed reinforcing rib frameworks, inner skins and outer skins, the inner skins and the outer skins are respectively attached to the inner side surfaces and the outer side surfaces of the reinforcing rib frameworks, and a plurality of sandwich foam blocks are filled in grids of the reinforcing rib frameworks; the ceiling comprises a sandwich layer plate, an upper skin and a lower skin, wherein the upper skin and the lower skin are respectively attached to the upper side surface and the lower side surface of the sandwich layer plate; the top frame, the bottom frame, the reinforcing rib framework, the inner skin, the outer skin, the upper skin and the lower skin are all molded integrally by carbon fiber composite materials; the reinforcing rib framework is of a hollow structure, and sandwich foam is filled in the reinforcing rib framework;
the underframe comprises two transverse bottom edge beams, two longitudinal bottom edge beams, an I-shaped bearing beam and a bottom net rack, wherein the transverse bottom edge beams and the longitudinal bottom edge beams are in U-shaped groove shapes; the bottom net rack is composed of an I-shaped bottom cross beam and a rectangular bottom longitudinal beam which are integrally formed, two ends of the I-shaped bottom cross beam are respectively assembled into the two longitudinal bottom edge beams and are fixedly connected through bolts, and the end part of the rectangular bottom longitudinal beam is assembled into the transverse bottom edge beam; and two sides of the I-shaped bearing beam are respectively assembled and connected with the bottom net rack and the side wall of the vehicle body.
2. The low-cost carbon fiber composite air-iron car body according to claim 1, wherein the sandwich foam, the sandwich foam blocks and the sandwich laminate are all made of hard fireproof foam.
3. The low-cost carbon fiber composite air-iron car body as claimed in claim 1, wherein the cross section of the sandwich laminate is in a trapezoidal shape with an opening at the bottom edge, and an inner edge is arranged on the inner side wall of the opening; the inner edge is connected to the outer top surface of the side wall of the vehicle body through a screw.
4. The low-cost carbon fiber composite air-iron car body according to claim 1, wherein the roof frame comprises two transverse roof side beams, two longitudinal roof side beams and a roof net frame, and the transverse roof side beams and the longitudinal roof side beams are in a U-shaped groove shape; the roof net rack is composed of an I-shaped roof beam and a rectangular roof longitudinal beam which are integrally formed, two ends of the I-shaped roof beam are respectively assembled into the two longitudinal roof side beams and are fixedly connected through bolts, and the end part of the rectangular roof longitudinal beam is assembled into the transverse roof side beam.
5. The low-cost carbon fiber composite air-rail car body as claimed in claim 1, wherein an embedded part located inside the sandwich foam block is embedded between the inner skin and the outer skin, and a threaded hole is reserved in the embedded part.
6. The low-cost carbon fiber composite air-iron car body as claimed in claim 5, wherein the embedded parts and the reinforcing rib frameworks are externally coated with foaming layers.
7. The low-cost carbon fiber composite air-iron vehicle body of claim 5, further comprising a flange and an outward-protruding sliding groove, wherein the flange and the outward-protruding sliding groove are both connected with the embedded part through bolts, and are both connected with the surface of the inner skin in a bonding manner; and the inside of the flange is sleeved with a handrail.
8. A process for manufacturing a low-cost air-iron car body made of carbon fiber composite material according to any one of claims 1 to 7, comprising the steps of:
(1) manufacturing a mould: manufacturing a wood mold according to the cross section outline of the vehicle body, wherein the length of the vehicle body is a multiple of the length of the wood mold; laying a composite material layer on the surface of the wood mould by hand to form a composite material mould;
(2) ply and outer skin fabrication: sequentially paving a fiber composite material, a carbon fiber prepreg and a vacuum bag in the composite material mould in the step (1), and placing the composite material mould into an oven for curing to form an outer skin;
(3) placing a sandwich foam block and a reinforcing rib framework: paving a transition bonding layer on the inner surface of the outer skin in the step (2), placing a reinforcing rib framework on the transition bonding layer, placing sandwich foam blocks in grids of the reinforcing rib framework, adopting a secondary bonding process to bond and connect the sandwich foam blocks and the reinforcing rib framework with the outer skin, then placing the sandwich foam blocks and the reinforcing rib framework in an oven, vacuumizing and then carrying out integral curing;
(4) manufacturing a laying layer and an inner skin: sequentially paving a transition bonding layer, a carbon fiber prepreg and a fiber composite material on the cured surfaces of the sandwich foam blocks and the reinforcing rib frameworks in the step (3), bonding and connecting the sandwich foam blocks and the reinforcing rib frameworks with the carbon fiber prepreg by adopting a co-bonding process, placing the sandwich foam blocks and the reinforcing rib frameworks into an oven, vacuumizing and then performing overall curing to form a vehicle body unit;
(5) and (4) repeating the steps (1) to (4) to generate a plurality of vehicle body units, and forming the vehicle body by assembling and connecting the vehicle body units.
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| CN201810435802.3A CN108622123B (en) | 2018-05-09 | 2018-05-09 | Low-cost carbon fiber composite air-iron vehicle body and manufacturing process |
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| CN201810435802.3A CN108622123B (en) | 2018-05-09 | 2018-05-09 | Low-cost carbon fiber composite air-iron vehicle body and manufacturing process |
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