CN112008920A - 用于生产火箭发动机复合材料壳体的芯模及其成型方法 - Google Patents
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Abstract
本发明涉及火箭发动机工装领域,公开了一种用于生产火箭发动机复合材料壳体的芯模,包括芯轴,芯轴外依次包裹有芯模内层(2)和芯模外层(3),芯模内层(2)由低密度固体浮力材料组成,芯模外层(3)由石英砂组成,且芯模内层(2)的直径小于复合材料壳体的后接头内径。本发明还公开了一种用于生产火箭发动机复合材料壳体的芯模的成型方法。本发明用于生产火箭发动机复合材料壳体的芯模及其成型方法,制备的芯模密度小、强度高、芯模挠度小,使用过程表面开裂、坍塌等缺陷较少,且内层可反复使用,成本低。
Description
技术领域
本发明涉及火箭发动机工装领域,具体涉及一种用于生产火箭发动机复合材料壳体的芯模及其成型方法。
背景技术
壳体芯模是生产复合材料壳体必备工装,传统芯模主要为砂芯模或石膏芯模,但这两种芯模均存在质量重,易开裂,不易拆卸等缺点,且难以反复使用,生产成本高。
发明内容
本发明的目的就是针对上述技术的不足,提供一种用于生产火箭发动机复合材料壳体的芯模及其成型方法,制备的芯模密度小、强度高、芯模挠度小,使用过程表面开裂、坍塌等缺陷较少,且内层可反复使用,成本低。
为实现上述目的,本发明所设计的用于生产火箭发动机复合材料壳体的芯模,包括芯轴,所述芯轴外依次包裹有芯模内层和芯模外层,所述芯模内层由低密度固体浮力材料组成,所述芯模外层由石英砂组成,且所述芯模内层的直径小于复合材料壳体的后接头内径。
一种用于生产火箭发动机复合材料壳体的芯模的成型方法,包括如下步骤:
A)制作芯模内层:将环氧树脂和固化剂混合均匀、脱气,再向混合物中加入空心玻璃微珠,混合均匀、静置,然后向模具中浇注,固化、脱膜后制得芯模内层,将并将制得的芯模内层与芯轴组装,形成一体;
B)制作芯模外层:将石英砂浆填充于的成型模具中,加压捣实,并对石英砂进行加热固化,固化后经脱膜依次得到前封头砂饼、筒身段砂饼和后封头砂饼;
C)芯模内外层连接:将步骤A)制得的芯模内层外表面全部粘贴脱膜布,然后在脱膜布表面涂刷一层搅拌均匀的石英砂浆,迅速将芯模外层组装至芯模内层相应位置,烘干,形成所需芯模。
优选的,所述步骤A)中,芯模内层成型使用机械搅拌器对环氧树脂进行搅拌,加热到60~80℃,保持0.5~1.5h,然后放入电热恒温真空干燥箱进行脱气0.5~1.5h,温度为60~80℃,排出环氧树脂中的微小气泡,再加入固化剂,搅拌0.4~0.6h,脱气0.8~1.2h,之后加入空心玻璃微珠,空心玻璃微珠的质量占比为10%~40%,混合均匀,静置,再将制得的混合物向模具中浇注,在70~90℃下保温0.8~1.2h,再在110~130℃下保温2~4h,脱模,获得芯模内层。
优选的,所述步骤B)中,石英砂浆配置过程如下:将聚乙烯醇和水按1:4~5质量分数比配制并加热至50~70℃取得石英砂粘合剂,将石英砂粘合剂与石英砂按1:5~7的质量分数比混合均匀制备成石英砂浆,且石英砂固化温度为100~140℃,固化时间为12~18h。
优选的,所述步骤C)中,烘干温度为100~140℃,烘干时间为14~16h。
优选的,所述脱膜布为聚四氟乙烯玻纤胶带。
优选的,所述固化剂为2-乙基-4-甲基咪唑或甲基四氢邻苯二甲酸酐。
本发明与现有技术相比,具有以下优点:
1、固体浮力材料强度高、密度小,有效减小芯模挠度,减少芯模在使用过程中表面开裂、坍塌等缺陷,有利于提高固体火箭发动机复合材料壳体内绝热层质量;
2、采用浮力材料+石英砂的组合方式,芯模容易成型,拆卸过程简单,有效提高生产效率,减少生产成本;
3、该芯模内层浮力材料可反复使用,降低芯模生产成本。
附图说明
图1为本发明用于生产火箭发动机复合材料壳体的芯模的结构示意图。
图中各部件标号如下:
芯轴1、芯模内层2、芯模外层3。
具体实施方式
下面结合具体实施例对本发明作进一步的详细说明。
实施例1
A)制作芯模内层2:
称取60Kg环氧树脂,使用机械搅拌器对环氧树脂进行搅拌,加热到60℃,保持0.5h,然后放入电热恒温真空干燥箱进行脱气0.5h,温度为60℃,排出环氧树脂中的微小气泡,再加入固化剂2-乙基-4-甲基咪唑,搅拌0.4h,脱气0.8h,之后加入6.7Kg的空心玻璃微珠,空心玻璃微珠型号为S60HS,混合均匀,静置,再将制得的混合物向模具中浇注,在70℃下保温0.8h,再在110℃下保温2h,脱模,获得芯模内层2,芯模内层2的直径小于复合材料壳体的后接头内径,将并将制得的芯模内层2与芯轴1组装,形成一体,本实施例制得的芯模内层2密度为0.6g/cm3,压缩强度达到85MPa;
B)制作芯模外层3:
称取10Kg水,加热至60℃,加入2Kg聚乙烯醇,经充分混合制备出石英砂粘合剂,称取70Kg石英砂,将制备好的石英砂粘合剂倒入石英砂中,在搅拌机中搅拌均匀后,制备出石英砂浆,将石英砂浆填充于芯模外层成型模中,升温至100℃、保温12h,脱模制得芯模外层3;
C)芯模内外层连接:将步骤A)制得的芯模内层2外表面全部粘贴脱膜布,所述脱膜布为聚四氟乙烯玻纤胶带,然后在脱膜布表面涂刷一层搅拌均匀的石英砂浆,迅速将芯模外层3组装至芯模内层2相应位置,烘干温度为100℃,烘干时间为14h,形成所需芯模,如图1所示。
实施例2
A)制作芯模内层2:
称取60Kg环氧树脂,使用机械搅拌器对环氧树脂进行搅拌,加热到70℃,保持1h,然后放入电热恒温真空干燥箱进行脱气1h,温度为70℃,排出环氧树脂中的微小气泡,再加入固化剂甲基四氢邻苯二甲酸酐,搅拌0.5h,脱气1h,之后加入10Kg的空心玻璃微珠,空心玻璃微珠型号为S38,混合均匀,静置,再将制得的混合物向模具中浇注,在80℃下保温1h,再在120℃下保温3h,脱模,获得芯模内层2,芯模内层2的直径小于复合材料壳体的后接头内径,将并将制得的芯模内层2与芯轴1组装,形成一体,本实施例制得的芯模内层2密度为0.57g/cm3,压缩强度达到68MPa;
B)制作芯模外层3:
称取10Kg水,加热至70℃,加入2Kg聚乙烯醇,经充分混合制备出石英砂粘合剂,称取70Kg石英砂,将制备好的石英砂粘合剂倒入石英砂中,在搅拌机中搅拌均匀后,制备出石英砂浆,将石英砂浆填充于芯模外层成型模中,升温至120℃、保温15h,脱模制得芯模外层3;
C)芯模内外层连接:将步骤A)制得的芯模内层2外表面全部粘贴脱膜布,所述脱膜布为聚四氟乙烯玻纤胶带,然后在脱膜布表面涂刷一层搅拌均匀的石英砂浆,迅速将芯模外层3组装至芯模内层2相应位置,烘干温度为120℃,烘干时间为15h,形成所需芯模。
实施例3
A)制作芯模内层2:
称取60Kg环氧树脂,使用机械搅拌器对环氧树脂进行搅拌,加热到80℃,保持1.5h,然后放入电热恒温真空干燥箱进行脱气1.5h,温度为80℃,排出环氧树脂中的微小气泡,再加入固化剂2-乙基-4-甲基咪唑,搅拌0.6h,脱气1.2h,之后加入40Kg的空心玻璃微珠,空心玻璃微珠型号为K46,混合均匀,静置,再将制得的混合物向模具中浇注,在90℃下保温1.2h,再在130℃下保温4h,脱模,获得芯模内层2,芯模内层2的直径小于复合材料壳体的后接头内径,将并将制得的芯模内层2与芯轴1组装,形成一体,本实施例制得的芯模内层2密度为0.62g/cm3,压缩强度达到76MPa;
B)制作芯模外层3:
称取10Kg水,加热至80℃,加入2Kg聚乙烯醇,经充分混合制备出石英砂粘合剂,称取70Kg石英砂,将制备好的石英砂粘合剂倒入石英砂中,在搅拌机中搅拌均匀后,制备出石英砂浆,将石英砂浆填充于芯模外层成型模中,升温至140℃、保温18h,脱模制得芯模外层3;
C)芯模内外层连接:将步骤A)制得的芯模内层2外表面全部粘贴脱膜布,所述脱膜布为聚四氟乙烯玻纤胶带,然后在脱膜布表面涂刷一层搅拌均匀的石英砂浆,迅速将芯模外层3组装至芯模内层2相应位置,烘干温度为140℃,烘干时间为16h,形成所需芯模。
本实施例1~3使用时,当复合材料壳体成型后,可用热水除去芯模外层3,然后拔出芯模内层2,留待下次使用,其中脱出芯模外层3热水温度为40~50℃。
本发明用于生产火箭发动机复合材料壳体的芯模及其成型方法,使用的固体浮力材料强度高、密度小,有效减小芯模挠度,减少芯模在使用过程中表面开裂、坍塌等缺陷,有利于提高固体火箭发动机复合材料壳体内绝热层质量;且采用浮力材料+石英砂的组合方式,芯模容易成型,拆卸过程简单,有效提高生产效率,减少生产成本;另外该芯模内层2浮力材料可反复使用,降低芯模生产成本。
Claims (7)
1.一种用于生产火箭发动机复合材料壳体的芯模,包括芯轴(1),其特征在于:所述芯轴(1)外依次包裹有芯模内层(2)和芯模外层(3),所述芯模内层(2)由低密度固体浮力材料组成,所述芯模外层(3)由石英砂组成,且所述芯模内层(2)的直径小于复合材料壳体的后接头内径。
2.一种如权利要求1所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:包括如下步骤:
A)制作芯模内层(2):将环氧树脂和固化剂混合均匀、脱气,再向混合物中加入空心玻璃微珠,混合均匀、静置,然后向模具中浇注,固化、脱膜后制得芯模内层(2),将并将制得的芯模内层(2)与芯轴组装,形成一体;
B)制作芯模外层(3):将石英砂浆填充于的成型模具中,加压捣实,并对石英砂进行加热固化,固化后经脱膜依次得到前封头砂饼、筒身段砂饼和后封头砂饼;
C)芯模内外层连接:将步骤A)制得的芯模内层(2)外表面全部粘贴脱膜布,然后在脱膜布表面涂刷一层搅拌均匀的石英砂浆,迅速将芯模外层(3)组装至芯模内层(2)相应位置,烘干,形成所需芯模。
3.如权利要求2所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:所述步骤A)中,芯模内层(2)成型使用机械搅拌器对环氧树脂进行搅拌,加热到60~80℃,保持0.5~1.5h,然后放入电热恒温真空干燥箱进行脱气0.5~1.5h,温度为60~80℃,排出环氧树脂中的微小气泡,再加入固化剂,搅拌0.4~0.6h,脱气0.8~1.2h,之后加入空心玻璃微珠,空心玻璃微珠的质量占比为10%~40%,混合均匀,静置,再将制得的混合物向模具中浇注,在70~90℃下保温0.8~1.2h,再在110~130℃下保温2~4h,脱模,获得芯模内层(2)。
4.如权利要求2所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:所述步骤B)中,石英砂浆配置过程如下:将聚乙烯醇和水按1:4~5质量分数比配制并加热至50~70℃取得石英砂粘合剂,将石英砂粘合剂与石英砂按1:5~7的质量分数比混合均匀制备成石英砂浆,且石英砂固化温度为100~140℃,固化时间为12~18h。
5.如权利要求2所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:所述步骤C)中,烘干温度为100~140℃,烘干时间为14~16h。
6.如权利要求2所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:所述脱膜布为聚四氟乙烯玻纤胶带。
7.如权利要求2所述用于生产火箭发动机复合材料壳体的芯模的成型方法,其特征在于:所述固化剂为2-乙基-4-甲基咪唑或甲基四氢邻苯二甲酸酐。
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