3D Printing Process And Electromechanical System Design Of Continuous Carbon Fiber Composite Material Components

In recent years,carbon fiber and its composite materials have been widely used in many industrial fields,due to a series of advantages such as light weight,high strength,electrical conductivity,high temperature resistance,fatigue resistance and easy processing.As a new type of electrieal material,carbon fiber reinforced polymer(CFRP)composites are rapidly growing in demand for wind power,electric vehicles,transmission cables,radars,etc.,and still have strong rising potential in the future.The application of 3D printing technology to CFRP composites enables rapid manufacturing of composite structural parts and shows a significant advantage in complex structural forming and reduced manufacturing costs.This paper is based on FDM(Fused Deposition Modeling)to explore the three-dimensional printing technology of CFRP composites.In order to ensure the fiber/resin bonding in composites and the electromechanical properties of molded parts,the hybrid printing process of continuous CFRP components was simulated,designed and tested,and an electromechanical system for 3D printing was developed to achieve rapid printing and performance improvement of composite components.The main achievements and innovations of this paper are as follows:(1)Study the 3D printing mechanism and the electro-mechanical characteristics of CFRP composites.The 3D printing mechanism of carbon fiber composites was revealed by analyzing the interfacial stress and adhesion work during fiber/resin extrusion.The mechanical and electrical properties of carbon fiber composites were studied from the microscopic point of view,and the relationship between printing parameters and tensile strength and electrical resistivity was established.(2)Proposal of a composite printing process based on simultaneous modified impregnation.The three-dimensional model of the nozzle was established by using the fluid finite element simulation software.The fluid characteristics of the CFRP preparation process were numerically simulated.The intermal flow fields,as well as temperature and pressure field distribution of the fiber/resin flowing through the nozzle were obtained.On this basis,an FDM printing process based on simultaneous modified impregnation was proposed,which can effectively improve the fiber/resin bonding and printing efficiency.(3)Design and implement a three-dimensional printing electromechanical system for continuous CFRP components.In order to realize 3D printing of composite materials,an online real-time mixing nozzle and mechanical transmission mechanism were developed.In addition,the hardware-software and control system were designed with ATmega2560 chip as the core processor,including power supply,communication module and motion-temperature control system,which provides an experimental platform for the molding and testing of composite components.(4)Continuous path planning design and process verification for composite printing.According to the continuity of fibers in CFRP and the characteristics of FDM process,the"one stroke" path planning method for continuous CFRP was systematically studied and the software codes were developed,including "long serpentine","ring-like interlocking",and print path planning for complex truss joint structures.Taking the synehronous modified impregnated 3D printing equipment as the experimental platform,the printing experiment of CFRP components under different parameters was carried out,which verified the superiority of the 3D printing technology of continuous CFRP components proposed in this paper.