Research On The Reliability Of Composite Components Embedded In Cables Under Thermal Load And Random Vibration Load

The composite material components embedded with cables and optical fibers have a wide range of development prospects in military aircraft and other industries.They have prominent advantages such as saving assembly space and achieving miniaturization of equipment,improving the efficiency of cable and optical fiber network assembly,and simple assembly technology.However,due to the large size of the cable and the optical fiber,a resin-rich region is likely to be formed around the buried cable,which makes the region prone to stress concentration and reduces the mechanical performance and reliability of the component.The service conditions of military equipment composed of components are often very poor,so when the structure of the embedded component is unreasonable(the cable diameter is too large,the spacing is too small,etc.),the embedded area is more likely to produce stress concentration when it is subjected to external loads,which affects the signal and The transmission of energy,or even destruction,greatly reduces the reliability of the equipment.Therefore,in order to ensure the reliability of the component and reduce the stress value of the component under external load,this paper combines the actual needs of relevant scientific research projects and product development,and takes the composite material component embedded in the cable as the research object to study the structural parameters of the component.The main research contents and results of the influence of component stress value under thermal load and random vibration load are as follows:(1)The influence rule of the embedded height of the cable on the stress value of the component is analyzed to determine the optimal embedded height of the cable in the composite material component.The ANSYS finite element software was used to establish the finite element model of cables embedded in composite materials with different heights,and then the models were simulated and analyzed under thermal load and random vibration load.The simulation results show that the composite material near the top corner of the resin-rich region of the component under the thermal cycling temperature load and random vibration load is subjected to greater stress,resulting in stress concentration.And when the cable is buried in the middle surface of the composite material,the stress values of the component under thermal cycle temperature load and random vibration load are 26.07 Mpa and 0.037 MPa respectively,which corresponds to the smallest comprehensive stress.(2)Through multi-parameter orthogonal simulation experiments,the degree of influence of relevant structural parameters on components was determined.Based on the analysis of the influence of the buried cable height on the stress of the component,five factors and four levels were designed for the remaining structural parameters of the component(thickness of the composite material,diameter of the buried cable,thickness of the insulating layer,number of buried cables,and distance between buried cables)simulation experiment.Based on the range analysis of the simulation results,it can be seen that the influence of the relevant structural parameters on the stress of the component is: buried cable diameter(1.8043)> buried cable number(0.9183)> buried cable spacing(0.7178)> insulation thickness(0.6699)> Composite material thickness(0.6586).(3)A mathematical relationship model of structural parameters and thermal stress value is constructed and relevant analysis conclusions are obtained.The stepwise regression method was used to analyze the 16 sets of orthogonal experimental data.Use JMP software to fit the mathematical relationship model of component structural parameters and component thermal stress,and evaluate and verify the obtained model.From the analysis results,we can see that the mathematical relationship model between the structural parameters of the components and the thermal stress values of the components is highly reliable and the fitting degree is high.The function mapping relationship between the structural parameters of the components and the thermal stress values of the components is preliminarily described.(4)Optimized design of relevant structural parameters and achieved optimized parameter combinations.Using genetic algorithm to optimize design of structural parameters of components,and get the optimal combination of structural parameters of the components is obtained: the thickness of the composite layer is 0.2988 mm,the diameter of the embedded cable is 0.60 mm,and the height of the embedded cable is the middle of the composite The thickness of the insulation layer is 0.09 mm,the number of embedded cables is 2,and the distance between embedded cables is 5.5mm.The theoretical value of the thermal stress of the component after optimization is 22.81 Mpa,and the experimental value is 23.171 Mpa,which is reduced by 2.90 Mpa compared with the maximum thermal stress value before optimization,the optimization rate is 11.12%,and the optimization effect is obvious.