CN108372693B - A kind of oversize single reflecting surface composite honeycomb sandwich structure panel and its manufacturing process - Google Patents

Abstract

The present invention proposes a composite honeycomb sandwich structure panel for ultra-large-size high-precision single-curvature reflective panels. This composite honeycomb sandwich structure panel includes three layers of hard aluminum plates, two layers of aluminum honeycomb cores, and profile skeletons for connection and support. . The overall realization process is the determination of panel block plan, the determination of splicing and slit plan of three-layer duralumin board, the calculation of shading, the unfolding of panel, the calculation of nail height, the three-layer aluminum board, panel and profile skeleton in high-precision nailing The positioning of the bed, the manufacture of the solid mold of the working board, the pre-stretching of the profile skeleton, the slotting of the honeycomb core, the adjustment of the nail bed, the laying of the sandwich structure panels layer by layer and the cementation under vacuum negative pressure. The invention is oriented to engineering applications, can effectively improve the forming rigidity and profile precision stability of super-large-size single-curvature reflective panels, and realize super-large-size single-curvature reflective panels with high precision, high stiffness, and light weight suitable for the near field of cylindrical surfaces The manufacturing target for the panel.

Description

A composite honeycomb sandwich structure panel with super-large single-curved reflective surface and its forming method

Technical field:

The invention proposes a composite honeycomb sandwich structure panel for a super-large-size single-curvature high-precision panel, in particular to a composite honeycomb sandwich structure panel for a cylindrical near-field super-large-size high-precision panel, which belongs to the field of mechanical engineering.

Background technique:

The near-field is the necessary equipment to realize the RCS measurement of the full-scale target characteristics. With the rapid development of satellite communication technology, aerospace stealth and anti-stealth technology, the demand and performance requirements for the large near-field are getting higher and higher. The reflective surface is used as a construction The foundation and key of large-scale near-field is constantly developing towards a larger area and higher precision, while improving the structural rigidity and surface accuracy stability of the ultra-large single-curvature reflective panel that constitutes the reflective surface has become a construction technical problem. The key to a breakthrough in the large near field.

The cylindrical near-field reflector measurement system can realize the accurate measurement of full-scale large-scale structures, and its advantage is that it can achieve a larger receiving area at a lower cost, but it is based on the existing pure honeycomb sandwich structure panel (as shown in Figure 1) There are certain deficiencies in forming rigidity and surface precision stability to manufacture ultra-large-size single-curvature reflective panels. On the basis of the honeycomb sandwich structure panel, a composite honeycomb sandwich structure panel based on the profile skeleton (as shown in Figure 2) is proposed, which can effectively improve the forming stiffness and surface precision stability of the ultra-large single-curvature reflective panel, and is beneficial to the construction of super-large Dimensional high-precision panels have important practical significance.

The honeycomb sandwich structure panel involved in this patent application is composed of three layers of hard aluminum plates, two layers of honeycomb, core glue and profile skeleton. It is laid layer by layer on the mold and sealed with a vacuum bag to form a negative pressure. It is formed after the cement is solidified. Composite honeycomb sandwich structure panel High-precision reflective panel (hereinafter collectively referred to as composite sandwich structure panel), the forming method is shown in Figure 1.

In addition, according to the applicant's understanding during the research and experiment process, the existing pure honeycomb sandwich structure panels mainly have the following problems when they are applied to the manufacture of ultra-large single-curvature reflective panels:

1. The rigidity of single-curvature reflective panels is lower than that of hyperbolic reflective panels of the same size and same curvature, and due to the size limitation of aluminum sheets, single large-size panels are manufactured by splicing technology, and the splicing joints will greatly reduce the manufacturing stiffness of the panels. The stability of the surface accuracy is poor.

2. For the previously manufactured high-precision reflective panel, in order to release the stress on the panel and improve the mold-fitting degree in the panel manufacturing process, the stress release technology of the three-layer duralumin plate was adopted, which further destroyed the integrity of the three-layer duralumin plate , It will also cause a decrease in the stability of the panel stiffness and surface accuracy.

3. The size of the reflective panel increases and the weight increases. The single-curvature reflective panel based on the existing pure honeycomb sandwich structure panel has poor profile accuracy stability under the hanging condition, thus affecting the performance of the entire measurement system.

Therefore, only using pure honeycomb sandwich structure panels to manufacture single-curved reflective panels can no longer meet the design requirements of super-large cylindrical near-field high-precision reflective surfaces. The stiffness of the single-curvature high-precision reflective surface and the stability of the surface accuracy.

Invention content:

1. Purpose: The purpose of this invention is to propose a composite honeycomb sandwich structure panel suitable for super-large single-curvature high-precision panels, so that the stiffness and profile accuracy stability of a single high-precision reflective surface are within the electrical design requirements. Within the range, the design goal of high precision and good electrical performance of the cylindrical near-field ultra-large reflector is achieved. The composite honeycomb sandwich structure panel refers to adding a profile skeleton to the honeycomb core of the honeycomb sandwich structure panel with a super-large single-curvature reflective surface, which plays a certain role in connecting and supporting the panels after splicing and slits, thereby improving the super-large Stiffness and surface accuracy stability of dimensional single-curvature panels.

This application mainly solves the problems in the manufacture of high-precision reflective panels of composite sandwich structure panels and the pre-forming and positioning of profile skeletons. From the perspective of engineering applications, it is hoped that fewer profile skeletons can be used, and the position and quantity of profile skeletons can be optimized and adjusted. Improve the stiffness of oversized single-curvature high-precision reflective panels.

2, technical scheme: the present invention proposes a kind of composite honeycomb sandwich structure panel that is used for the single-curvature panel of super-large size (single panel size is super-large size more than 6 square meters) single-panel area reaches 6 square meters, this A composite honeycomb sandwich structure panel is composed of three layers of hard aluminum plates, two layers of aluminum honeycomb cores and profile skeletons for connection and support;

The three-layer duralumin board is the working board 1, the middle board 2 and the back board 3 respectively, the two-layer aluminum honeycomb core is the honeycomb core 4 between the working board 1 and the middle board 2, the middle board 2 and the back board 3 Between the honeycomb core 5, a profile skeleton 6 is added between the honeycomb core 5 and the back panel 3. Described profile skeleton 6 selects the section bar that is T-shaped for use, and T-shaped profile adopts two L-shaped profiles back-to-back structure (seeing 21 in Fig. 2), and the honeycomb core after slotting (seeing 22 in Fig. The cemented connection has the advantages of high rigidity, sufficient material utilization, and high structural efficiency. The thickness of the working plate 1 is 1.5 mm, the thickness of the connecting plate 2 is 1 mm, the thickness of the back plate 3 is 1.5 mm, and the thickness of the honeycomb core 4 and the honeycomb core 5 is 60 mm.

The manufacturing method of the composite honeycomb sandwich structure panel includes: determination of panel block plan, determination of splicing and slit plan of three-layer hard aluminum plates, calculation of shrinkage, expansion of single panel, calculation of nail height, three-layer The positioning of aluminum plates and profiles on high-precision nail beds, the manufacture of solid molds for single work plates, the pre-stretching of profiles, the slotting of honeycomb cores, and the sequential laying and bonding of forming. Among them, the splicing and slit scheme of the three-layer aluminum plate is the element that directly affects the lamination degree and rigidity of the sandwich structure panel. The solid mold of the working plate is the key point to realize the preliminary forming of the profile skeleton. Positioning is the key to manufacturing ultra-large single-curvature high-precision panels.

The present invention proposes a method for forming a composite honeycomb sandwich structure panel with a super-large single-curved reflective surface, and the specific steps are as follows:

Step (1) Establish a three-dimensional model of the aluminum plate according to the busbar equation

According to the block plan in the electrical design result, the panel numbering of the block back, the left side is an odd number, and the right side is an even number, and the present invention uses one of the panels (here, a single panel is a composite honeycomb sandwich structure after the reflective surface block) The panel as a whole, including the working plate 1, the intermediate plate 2, the back plate 3, the honeycomb core 4 and the honeycomb core 5, and the profile skeleton 6) is used as an example to introduce the composite honeycomb sandwich structure panel and its forming method. In the YOZ plane coordinate system sketch editing environment of Catia (interactive CAD/CAE/CAM system) wireframe and surface design mode, import the busbar equation of the panel to draw the busbar, and the surface formed by stretching along the normal direction of the busbar is The theoretical surface of the overall panel; in the XOY plane coordinate system sketch editing environment, import the outline of the panel, stretch and divide the theoretical surface of the overall panel to obtain the theoretical surface of the working panel 1. Still in the XOY plane coordinate system sketch editing environment, import the coordinates of the measuring hole of the working board 1, draw the sketch of the measuring hole with a diameter of 1.2mm, stretch it and cut it on the theoretical surface of the working board 1;

Step (2) Spatial geometric expansion of the theoretical surface of a single work plate and its positioning on the nail bed

Based on the highest point of the arch height of the theoretical curved surface of the working panel 1 as the base point, establish the tangent plane of the theoretical curved surface of the working panel 1 and the design coordinate system (take the highest point of the arch height of the theoretical curved surface of the working panel 1 as the origin, and use the work passing through the origin The coordinate system established by the positive normal direction of the tangent plane of the theoretical surface of the plate 1 is the Z axis direction is the design coordinate system), and the highest point of the arch height is measured and the center of the manufacturing coordinate system (the geometric center of the theoretical surface of the working plate 1 is the origin, parallel The coordinate system established on the tangent plane of the theoretical curved surface of the working board 1 and the positive normal direction of the plane passing through the origin is the Z-axis direction is the manufacturing coordinate system), draw four points pointing to the highest point of the arch height in the design coordinate system XOY plane The small triangle is used to mark the highest point of the arch height, and the sketch of the small triangle is stretched and cut out on the theoretical surface of the working board 1. Expand the theoretical curved surface of the working board 1 on the tangent plane to obtain the expanded material of the working board 1. Open the dxf file in Auto CAD, determine the manufacturing center of the nail bed, and use a circle with a radius of 6 mm to represent the ball-head nail column, and use the nail bed manufacturing center as the base point to perform a rectangular array with a spacing of 50 mm, according to the work obtained from the previous measurement The relative position of the highest point of the arch height of the board 1 and the manufacturing center of the nail bed is introduced into the unfolded material of the work board 1, and the specifications of the nail bed diagram are determined according to the size of the work board 1. According to the shrinkage calculation (see step 1 of the specific embodiment for the calculation method), the corresponding edge of the outline of the working plate 1 is translated to obtain the nail bed layout diagram of the intermediate plate 2 and the back plate 3, and the overall nails of the three-layer duralumin plate are obtained. bed layout.

Step (3) Nail height calculation

Use the nail height calculation software to calculate the nail height. Nail height calculation software is a rapid design software researched and written by the project team in order to reduce the amount of manual calculation and improve design efficiency. In this software, the focal length of the panel, surface type, coordinate data, nail bed specifications and other data are input, and the software is pre-written. The imported nail height algorithm can calculate the nail height data corresponding to each nail column on the dot matrix nail mold, and output the nail height data into a standard file.

Step (4) Slit stress relief and laser cutting sheet

In Catia, establish the overall model of the expanded material of the working board 1 and the theoretical surface mold of the working board 1, and save it as a stp format file. Import the ABAQUS finite element analysis software to carry out the simulation of the pressing of the working plate 1, and obtain the stress cloud diagram of the working plate 1 after forming. According to the stress distribution obtained from the pressing simulation results, determine the position and length of the slit of the working plate 1, and perform slit treatment on the three-layer duralumin plate. A minimum spacing of 100 mm is guaranteed to improve the overall rigidity of the panel. The three-layer duralumin boards after slits are arranged in a single layer in a sheet drawing of a specified size to obtain a blanking map, and the three-layer duralumin board boards are obtained by laser cutting.

Step (5) Positioning and pre-stretching of profile skeleton

Establish the stp model of the composite sandwich structure panel, import the ABAQUS finite element analysis software to carry out the stiffness calculation simulation experiment, select the optimal position and quantity of the profile skeleton, and measure the relative position of the geometric center of the profile skeleton 6 and the design coordinate system. According to the relative position between the geometric center of the profile skeleton 6 and the design coordinate system, select the location of the positioning hole of the profile skeleton 6 in the nail bed layout diagram, and measure the relative position between the positioning hole of the profile skeleton 6 and the center of the design coordinate system. Draw a sketch of the positioning hole on the bottom surface of the profile skeleton 6 and cut it out, and obtain the position of the positioning hole of the profile skeleton 6 after unfolding. Take the theoretical curved surface of the working plate 1 as the digital model, process a solid mold and draw the outline of the theoretical curved surface of the working plate 1 on the mold surface, and determine the pre-stretching of the profile skeleton 6 according to the relative position of the geometric center of the profile skeleton 6 and the design coordinate system position and carry out pre-stretching processing to the profile skeleton 6 to improve the degree of pasting.

Step (6) laying sandwich structure panels layer by layer

The layer-by-layer laying of sandwich structure panels described in this step is the main process of manufacturing high-precision reflective panels:

(1) Lay the backing plate 7 on the nail bed envelope surface adjusted according to the nail height data calculated in step (3) and position it;

(2) Place the front of the working plate 1 on the backing plate 6 coated with lubricating oil, and use the positioning pins and positioning holes for positioning;

(3) Apply glue on the back of the working board 1, and lay the honeycomb core 4 on the glue layer;

(4) apply glue on the side of the connecting plate 2 facing the working plate, and then lay the glued surface on the honeycomb core 4 according to the positioning position;

(5) Apply glue on the other side of the intermediate plate 2, lay the honeycomb core 5 on the glue layer, and slot the position corresponding to the back plate profile skeleton 6 on the honeycomb core 5;

(6) Place the glue-coated back plate 3 pre-glued with the profile skeleton 6 with the glue side down on the honeycomb core 5 and position it, thus completing the layer-by-layer laying process of the sandwich structure panels.

(7) Cover the vacuum-sealed bag 10 at last on the marble platform where the dot-matrix nail mold is placed, and seal the sealed bag and the marble platform together with an adhesive tape, vacuumize with a vacuum system, and keep the atmospheric pressure at about 0.033Mpa to reach 48 hours Later, a large-scale high-precision single composite sandwich structure panel was formed.

The advantages and effects of the present invention are: the present invention adopts a forming method based on the principle of "discrete nail mold, vacuum negative pressure, honeycomb interlayer, stress release" combining high-precision panel forming process and profile pre-stretching forming process to manufacture super large size high The advantage of the precision single-curvature composite sandwich structure panel is that the profile skeleton can be preliminarily molded under the condition of continuous surface through the pre-stretching forming process, which is beneficial to reduce the springback of the cemented overall structure and improve the mold-fitting on the high-precision nail bed If necessary, the profile skeleton can be slit to further improve the molding degree of the profile skeleton; then use vacuum negative pressure to cement the envelope surface formed by the high-precision flexible lattice nail mold, and obtain a three-layer hardened surface after curing and forming. The composite double-sandwich structure panel with two-layer honeycomb core and profile skeleton of aluminum plate has high rigidity, which is conducive to maintaining the precision of the profile; it can finally realize the high-precision, high-rigidity, and light-weight technology required by super-sized single-curvature antennas Target.

This structure is a composite double sandwich structure panel with three layers of duralumin board, two layers of honeycomb core and profile skeleton. 4 and the honeycomb core 5 are bonded, the honeycomb is grooved, and then the back plate of the pre-glued profile skeleton 6 is bonded to the honeycomb core 5, so that the accuracy of the working board is not affected, and the overall strength of the honeycomb sandwich structure panel can be increased. Rigidity, so that the whole structure maintains good accuracy and stability.

Description of drawings:

Figure 1 is a schematic diagram of a pure honeycomb sandwich structure panel.

Fig. 2 is a schematic diagram of a composite honeycomb sandwich structure panel.

Figure 3 is a layout diagram of the overall nail bed.

Figure 4 is a graph of spike height data.

Fig. 5 is a flow chart of nail height calculation.

Fig. 6 is a schematic diagram of profile skeleton pre-stretching.

The symbols involved in the figure are explained as follows:

Working board 1, connecting board 2, back board 3, honeycomb core 4, honeycomb core 5, profile skeleton 6,

T-shaped profile 21, honeycomb T-shaped groove 22, plate positioning round hole 31, positioning long hole 32,

No-hole lugs 33 for handling, layout of working plate 1 nail bed 34, layout of intermediate plate 2 nail beds 35,

The layout of the backplane 3 nail bed 36, the selected profile positioning hole 37, the solid mold 61,

Working board 1 theoretical curved surface contour line 62, T-shaped profile drawing shape 63;

Detailed ways:

The present invention proposes a composite honeycomb sandwich structure panel for ultra-large-size high-precision single-curvature reflective panels. This composite honeycomb sandwich structure panel is composed of three layers of duralumin boards, two layers of honeycomb cores and a profile skeleton for connection and support. The three-layer hard aluminum board is the working board 1, the intermediate board 2 and the back board 3, and the two-layer honeycomb core is the honeycomb core 4 between the working board and the middle board and the honeycomb core 4 between the middle board and the back board. The honeycomb core 5, the profile skeleton 6 added between the honeycomb sandwich core 5 and the back plate 3.

The present invention is a composite honeycomb sandwich structure panel with a super-large size and high-precision single-curvature reflective panel. The overall realization process is the determination of the panel block plan, the splicing of three-layer hard aluminum plates and the determination of the slotting plan, the calculation of shading, Unfolding of single panel, calculation of nail height, positioning of three-layer duralumin board and profile skeleton on lattice nailing mold, manufacturing of solid mold for work plate, pre-stretching of profile skeleton, slotting of honeycomb core, and positioning of lattice nailing mold Adjustment, laying three-layer hard aluminum plate, two-layer honeycomb core and profile skeleton layer by layer on the adjusted dot matrix nail mold for bonding, after sealing, vacuuming, and holding pressure for a certain period of time, after the glue is cured, a super-sized single curvature is formed Reflective panels, thus realizing the manufacture of ultra-large single-track high-precision composite sandwich structure panels. The specific forming method of the composite sandwich structure panel is as follows:

Step (1): Generate four basic design files according to the electrical design results: 1), the outline of the tooth in the Catia coordinate system: draw the outline of the tooth according to the coordinate data of the tooth in the electrical design coordinate system in the electrical design result, and perform coordinate transformation, Obtain the outline of the lower teeth in the catia coordinate system; 2), shrink distance: draw the overall outline of the teeth of the panel in Catia (interactive CAD/CAE/CAM system), offset 120 mm backward, and measure the maximum of the teeth of the panel before and after the offset The reduction distance is multiplied by the safety factor (1.2~1.5) to obtain the reduction distance of the side teeth of the back panel. The division line coordinate data given in the design results is calculated considering the division line coordinates after the offset of the splicing gap, and the panel outline is divided into blocks to generate the projected rectangular outline of a single reflective surface. In order to carry out the follow-up work in an orderly manner, number the divided panels, the panel on the left side of the symmetry axis is an odd number, and the right side is an even number; 4), measuring hole and hanging point position coordinates: according to the coordinates of the dividing line after offset And the vertical distance between the adjacent edges of the solid part of the panel after the block, determine the position coordinates of the panel measurement hole and the hanging point of the back panel, and the vertical distance from the center of the measurement hole to the adjacent edge of the solid part of the panel (excluding side teeth) is the length of the solid part of the panel 2/9 of;

In the YOZ plane coordinate system sketch editing environment of Catia (interactive CAD/CAE/CAM system) wireframe and surface design mode, import the busbar equation of the panel to draw the busbar, and the surface formed by stretching along the normal direction of the busbar is The theoretical surface of the overall panel; in the XOY plane coordinate system sketch editing environment, import the outline of the panel, stretch and divide the theoretical surface of the overall panel to obtain the theoretical surface of the working panel 1. Still in the XOY plane coordinate system sketch editing environment, import the coordinates of the measuring hole of the working board 1, draw the sketch of the measuring hole with a diameter of 1.2mm, stretch it and cut it on the theoretical surface of the working board 1;

Step (2): Taking the highest point of the arch height of the theoretical curved surface of the working panel 1 as the origin, establish the tangent plane and the design coordinate system of the theoretical curved surface of the working panel 1 (take the highest point of the arch height of the theoretical curved surface of the working panel 1 as the origin, and take The coordinate system established by the positive normal of the tangent plane of the theoretical surface of the working plate 1 passing through the origin is the Z-axis direction is the design coordinate system), and the highest point of the arch height and the center of the manufacturing coordinate system are measured (based on the geometry of the theoretical surface of the working plate 1 The center is the origin, parallel to the tangent plane of the theoretical curved surface of the working board 1 and the positive normal direction of the plane passing through the origin is the Z-axis direction, and the coordinate system established is the manufacturing coordinate system), draw four directions in the design coordinate system XOY plane The small triangle at the highest point of the arch height is used to mark the highest point of the arch height, and the sketch of the small triangle grass is stretched and cut out on the theoretical surface of the working board 1. After cutting the dxf file, determine the manufacturing center of the nail bed, use a circle with a radius of 6 mm to represent the ball-head nail column, and develop the theoretical curved surface of the working board 1 on the nail bed manufacturing center plane to obtain the expanded material of the working board 1. Make a rectangular array with a pitch of 50 mm in Auto CAD, and import the expanded material of the working board 1 according to the relative position of the highest point of the crown height of the working board 1 and the manufacturing center of the nail bed measured before, and make the working board 1 in There are 2 to 3 rows of nail columns outside the edge after positioning on the nail bed to ensure the forming accuracy of the edge of the working plate 1. Determine the positioning hole at the position of the nail post as close as possible to the edge of the working board 1, wherein the positioning hole on one side is a round hole 31, and the positioning hole on the other side is a long hole 32, and the round holes and the long holes are in the same row or column on the nail post. If the panel area is too large, lugs 33 can be added to facilitate the workmen to carry the sheet. Project the theoretical curved surface of the working board 1 to the tangent plane sketch of the design coordinate system, determine the position of the ear piece by the relative position between the positioning hole and the center of the design coordinate system, draw the ear piece and connect it with the projection of the theoretical curved surface of the working board 1 to form a closed curve , Exit sketch editing and stretch, cut the theoretical surface of working board 1 to get the theoretical surface of working board 1 with lugs; draw a positioning hole with a diameter of 10.2 mm in the design coordinate system XOY plane, exit sketch editing and stretch, cut The theoretical curved surface of the working plate 1 with the lugs is then unfolded in the design coordinate system to obtain the unfolded diagram of the positioning hole; according to the relative position of the positioning hole and the center of the manufacturing coordinate system, the position of the unfolded positioning hole is imported into the nail bed layout diagram, One side of the positioning hole is a round hole 31, and one side of the positioning hole is a long hole 32, and for the convenience of the workers to carry the sheet, if necessary, a non-porous ear piece 33 can be added; in order to reduce the number of positioning holes, generally the three-layer duralumin plate The positioning holes are designed at the same stud post. According to the distance reduction calculated in step (1), translate the corresponding side of the nail bed layout diagram 34 of the working board 1 to obtain the nail bed layout diagram 35 of the middle joint board 2 and the nail bed layout diagram 36 of the back board 3, and thus obtain three layers The overall nail bed layout of the hard aluminum plate (as shown in Figure 3).

Step (3): The nail height calculation is completed by the nail height calculation software. The software has four modules: project management, panel management, nail height calculation and data import. For the first calculation of nail height, the project needs to be established first, and then calculated in the nail height calculation module. Need to use nail height calculation module. Firstly, build the project in the project management module, set the surface type as parabolic cylinder, input the focal length of the surface as 20000 mm, the geometric parameters of the panel as 20000 mm × 18000 mm, and the edge gear type as independent edge gear, that is, the panel and the edge gear are manufactured separately, and the panel Blocks are divided into 5 rows and 7 columns. In the nail height calculation module, select the project name established above, input the panel number and the coordinates of the panel dividing line after considering the seam corresponding to the panel to be calculated to determine the position of the panel in the overall panel, and the top of the nail column is hemispherical , the radius of the ball head is 20mm, import the nail bed diagram (excluding the three-layer duralumin plate) and save the parameters, click calculate nail height to start calculation, the calculation principle is to match the discrete lattice nail mold with the theoretical surface of the panel, and then calculate The discrete heights of each nail column at the theoretical surface of the panel are obtained, and the envelope surface formed by the discrete lattice nail mold obtained in this way is the theoretical surface of the panel. After the calculation is completed, the standard nail height data file is output. Part of the nail height data is shown in Figure 4 below. The X and Y coordinates are the position of the nail column relative to the center of the manufacturing coordinate system, and the nail column coordinates at the center of the manufacturing coordinate system are X=0Y=0. To calculate the nail height value, it is necessary to adjust The height of the nail column on the dot matrix nail mold, the flow chart of nail height calculation is shown in Figure 5.

Step (4): In Catia, establish the overall model of the unfolded material of the working board 1 and the theoretical curved surface mold of the working board 1, and save it as a stp format file. Import the ABAQUS finite element analysis software to carry out the pressing simulation of the working plate 1, and obtain the stress cloud diagram of the working plate 1 after forming. According to the stress distribution obtained from the pressing simulation results, determine the position and length of the slit of the working plate 1, and perform slit treatment on all three layers of hard aluminum plates. The gap between the joints should be at least 100 mm to improve the overall rigidity of the panel. According to the seam position of each laminate, the position of the positioning hole is selected, and the relative position of the positioning hole on the nail bed and the center of the manufacturing coordinate system is obtained by measuring, so as to obtain the relative position of the positioning hole and the center of the design coordinate system. Arrange the three-layer duralumin boards after slits in this step in a single layer in the sheet drawing of a specified size to obtain the blanking map, and obtain the three-layer duralumin board sheet by laser cutting.

Step (5): Establish the stp model of the panel of the composite sandwich structure, import the ABAQUS finite element analysis software to carry out the stiffness calculation simulation experiment, select the optimal position and quantity of the profile skeleton 6, and measure the geometric center of the profile skeleton 6 and the design coordinate system relative position. According to the relative position between the geometric center of the profile frame 6 and the design coordinate system, select the positioning hole position 37 of the profile frame 6 in the nail bed layout diagram, and measure the relative position between the profile frame 6 positioning hole and the center of the design coordinate system. Draw a sketch of the positioning hole on the bottom surface of the profile skeleton 6 and cut it out, and obtain the position of the positioning hole of the profile skeleton 6 after unfolding. Taking the theoretical curved surface of the single working board 1 as the digital model, process a solid mold 61 and draw the outline 62 of the theoretical curved surface of the working board 1 on the mold surface, and determine the profile skeleton according to the relative position of the geometric center of the profile skeleton 6 and the design coordinate system 6 pre-stretching position T-shaped profile drawing 63, the profile skeleton 6 is pre-stretched (as shown in Figure 6) processing, so that it can be better mold-fitting, and can be slotted to improve the degree of mold-fitting if necessary. Open T-shaped groove 22 to honeycomb 5, can not perk when making it embedded profile skeleton.

Step (6): Positioning on the nail bed (lattice nail mold 8 ) according to the relative positions of the profile frame 6 , the back plate 3 and the center of the design coordinate system, and pre-cementing the profile frame 6 and the back plate 3 .

The layer-by-layer laying of sandwich structure panels described in this step is the main process of manufacturing high-precision reflective panels:

(1) Lay the backing plate 7 on the nail bed envelope surface adjusted according to the nail height data calculated in step (3) and position it;

(2) Place the front of the working plate 1 on the backing plate 6 coated with lubricating oil, and use the positioning pins and positioning holes for positioning;

(3) Apply glue on the back of the working board 1, and lay the honeycomb core 4 on the glue layer;

(4) apply glue on the side of the connecting plate 2 facing the working plate, and then lay the glued surface on the honeycomb core 4 according to the positioning position;

(5) Apply glue on the other side of the intermediate plate 2, and lay the honeycomb core 5 on the glue layer;

(6) Place the glue-coated back plate 3 pre-glued with the profile skeleton 6 with the glue side down on the honeycomb core 5 and position it, thus completing the layer-by-layer laying process of the sandwich structure panels.

(7) Cover the vacuum-sealed bag at last on the marble platform where the dot matrix nail mold is placed, and seal the sealed bag 10 and the marble platform together with an adhesive tape, vacuumize with a vacuum system, and keep the atmospheric pressure at about 0.033Mpa to reach 48 hours Later, a large-scale high-precision single-curved composite sandwich structure panel was formed.

The ultra-large size high-precision single-curved composite honeycomb sandwich structure panel reflective panel of the present invention has a working plate thickness of 1.5 mm, a middle plate thickness of 1 mm, a back plate thickness of 1.5 mm and a honeycomb core thickness of 60 mm.

Claims (9)

1. a kind of oversize single reflecting surface composite honeycomb sandwich structure panel, it is characterised in that: the composite honeycomb interlayer knot Structure panel is made of three layers of duralumin plate, two layers of aluminium honeycomb core and sectional materials cage for connecting and supporting；

Three layers of duralumin plate is respectively working plate, middle fishplate bar and backboard, and two layers of aluminium honeycomb core is between working plate and middle fishplate bar The first honeycomb core, the second honeycomb core between middle fishplate bar and backboard adds sectional materials cage between the second honeycomb core and backboard； It is the profile of T shape that the sectional materials cage, which selects section, and T shape profile uses two L-shaped section back to back structure, with the bee after fluting Nest core, duralumin plate are connected by the way of cementing；

Oversize refers to monolithic panel size at 6 square metres or more.

2. a kind of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 1, feature exist In: the working plate is 1.5 millimeters with a thickness of 1 millimeter, back plate thickness with a thickness of 1.5 millimeters, middle fishplate bar；First honeycomb core and Two honeycomb cores with a thickness of 60 millimeters.

3. a kind of manufacturing process of oversize single reflecting surface composite honeycomb sandwich structure panel, which is characterized in that step is such as Under:

Step (1) establishes the threedimensional model of aluminium sheet according to bus equation

According to the segment partition scheme in electrical design result, piecemeal rear panel is numbered, left side is odd number, and right side is even number；In Under Catia wire frame and the YOZ plane coordinate system Sketching environment of curved design mode, the bus equation for importing panel draws mother Line is formed by the theoretical curved surface that curved surface is integral panels along the normal extension of this bus；It is compiled in XOY plane coordinate system sketch It collects under environment, imports the contour line of the panel, stretch and rear obtained curved surface simultaneously is split to the theoretical curved surface of integral panels For the plate theory curved surface that works；Still under XOY plane coordinate system Sketching environment, working plate measured hole coordinate is imported, is drawn straight The measured hole sketch that diameter is 1.2 millimeters is stretched and is cut on work plate theory curved surface；

The space geometry expansion and the positioning on nail bed of step (2) monolithic work plate theory curved surface

Using the sagitta highest point of the work plate theory curved surface of panel as basic point, work plate theory tangent plane to a surface and design are established Coordinate system, and the relative position of sagitta highest point Yu Ding Chuan manufacturing center is measured, four are drawn in design coordinate system XOY plane A small triangle for being directed toward sagitta highest point stretches the sketch of small triangle and to mark sagitta highest point in working plate It is cut on theoretical curved surface；It organizes work in tangent plane plate theory curved surface, obtains working plate spread material；It is beaten in Auto CAD Dxf file is opened, determines Ding Chuan manufacturing center, bulb post is indicated with the circle that radius is 6 millimeters, using Ding Chuan manufacturing center as base The rectangular array that line space is 50 millimeters is clicked through, according to the working plate sagitta highest point and Ding Chuan manufacturing center measured before Relative position, import working plate spread material, and according to work board size determine nail bed figure specification；According to contracting away from being calculated Contracting away from being translated to obtain the nail bed layout of middle fishplate bar and backboard to working plate profile corresponding sides, obtain three layers of duralumin plate Overall nail bed layout；

Step (3) nail is high to be calculated

It is high that nail is calculated using high software for calculation is followed closely；Focal length, curved surface type, coordinate data, the nail of input panel in the software The data of bed specification, it is high that the high algorithm of nail being previously written by software can calculate nail corresponding to each post on dot matrix dolly set Data, and high data will be followed closely and form normative document output；

Step (4) crack stress release and laser cutting plate

The overall model that working plate spread material and the plate theory curve mold that works are established in Catia saves as stp format text Part；It imports ABAQUS finite element analysis software progress working plate and overlays emulation, the Stress Map after obtaining working plate forming；According to The obtained stress distribution situation of simulation result is overlayed, determines position and length of cracking that working plate cracks, and to three layers of duralumin Plate carries out processing of cracking, and three layers of duralumin plate position of cracking interlocks, the minimum spacing for guaranteeing to have 100 millimeters of cracking in the same direction, to mention The overall stiffness of high panel；Three layers of duralumin plate after cracking are arranged in respectively in predetermined size plate figure with single layer, are obtained down Material figure, the method being cut by laser obtain the plate of three layers of duralumin plate；

The positioning of step (5) sectional materials cage and prestretching shape

The stp model of composite sandwich structural panel is established, ABAQUS finite element analysis software is imported and carries out Rigidity Calculation simulation in fact It tests, selects the optimal location and quantity of sectional materials cage, and the geometric center for measuring sectional materials cage is opposite with design coordinate system Position；According to the relative position of the geometric center of sectional materials cage and design coordinate system, sectional materials cage is selected in nail bed layout Position of positioning hole, and measure sectional materials cage location hole and design coordinate system center relative position, the drafting type in Catia The location hole sketch of material skeleton bottom surface is simultaneously cut out, and sectional materials cage position of positioning hole is obtained after expansion；To work, plate theory curved surface is Digital-to-analogue processes a tangible mold and depicts work plate theory curved surface profile line on the mold surface, several according to sectional materials cage What center and the relative position of design coordinate system determine the position of sectional materials cage prestretching forming and are pulled into advance to sectional materials cage Shape processing is to improve mold degree；

Step (6) is successively laid with sandwich panel

It is oversize single reflecting surface composite honeycomb sandwich structure panel that sandwich panel is successively laid with described in this step The process of manufacture:

(1) backing plate is laid on the nail bed enveloping surface mixed up according to the high data of nail being calculated in step (3) and is positioned；

(2) working plate front is placed on the backing plate for being coated with lubricating oil, is positioned using positioning pin and location hole；

(3) in working plate backsizing, the first honeycomb core is laid on glue-line；

(4) in a face gluing of the middle fishplate bar towards working plate, coated face is then laid in the first honeycomb core according to position location On；

(5) in middle fishplate bar another side gluing, the second honeycomb core is laid on glue-line, backboard profile is corresponded on the second honeycomb core It slots the position of skeleton；

(6) the glue-coated cementing backboard glue surface for having sectional materials cage in advance is placed in downwards on the second honeycomb core and is positioned, until This completes the layer-by-layer process of deployment of sandwich panel；

(7) finally vacuum seal bag is covered in the marble platform for being placed with dot matrix dolly set, blend compounds band is by hermetic bag and Dali Stone platform is sealed, and is vacuumized with pumped vacuum systems, and atmospheric pressure is maintained at after 0.033Mpa reaches 48 hours, is formed Oversize single reflecting surface composite honeycomb sandwich structure panel；

Wherein, oversize refers to monolithic panel size at 6 square metres or more.

4. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: four Basic Design files are generated according to electrical design result:

1.1, the following gear tooth profile of Catia coordinate system: according to the heel teeth number of coordinates under electrical design coordinate system in electrical design result According to heel teeth profile is drawn, it is coordinately transformed, obtains the following gear tooth profile of catia coordinate system；

1.2, contracting away from: in Catia draw panel entirety heel teeth profile, backward deviate 120 millimeters, measurement offset front-back edges of boards The maximum contracting of tooth is away from obtaining the contracting of backboard heel teeth away from, middle fishplate bar heel teeth contracting away from contracting for backboard heel teeth multiplied by safety coefficient 1.2~1.5 Away from half；

1.3, consider the cut-off rule in splicing gap: being calculated according to the cut-off rule coordinate data provided in electrical design result and consider to spell Segmentation line coordinates after the offset of seam gap carries out piecemeal to face plate profiles, generates the projection rectangle contour line of monolithic reflecting surface；

1.4, measured hole and hanging point position coordinate: according to segmentation line coordinates and piecemeal rear panel entity part neighboring edge after offset Vertical range, determine panel measuring hole and backboard hanging point position coordinate, the measured hole center of circle to panel entity part neighboring edge Vertical range be panel entity part length 2/9.

5. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: in step (2), using the sagitta highest point for the plate theory curved surface that works as origin, to cross the work of the origin Plate theory tangent plane to a surface positive normal direction is that the coordinate system that Z-direction is established is design coordinate system.

6. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: using the geometric center for the plate theory curved surface that works as origin, be parallel to work plate theory curved surface tangent plane and mistake The plane positive normal direction of the origin is that the coordinate system that Z-direction is established is manufacture coordinate system.

7. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: in step (2), working plate positions on nail bed 2 to 3 nail columns outside back edge, guarantees working plate The forming accuracy at edge；It is provided with location hole at the post position at working plate edge, wherein side location hole is circular hole, the other side Location hole is long hole, and circular hole and long hole are on same row or same row post.

8. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: in step (2), by work plate theory curved surface projection into design coordinate system tangent plane sketch, by fixed The relative position at position hole and design coordinate system center determines the position of auricle, draws auricle and is allowed to throw with work plate theory curved surface Shadow is linked to be closed curve, exits Sketching and stretches, and cuts work plate theory curved surface, and it is bent to obtain the work plate theory with auricle Face；The location hole that diameter is 10.2 millimeters is drawn in design coordinate system XOY plane, is exited Sketching and is stretched, cutting belt The work plate theory curved surface of auricle, is then unfolded in the case where designing coordinate system, obtains location hole expanded view；According to location hole and nail bed The relative position of manufacturing center imports the position of positioning hole after expansion in nail bed layout, for worker's plate easy to carry, Add non-porous auricle；In order to reduce the quantity of location hole, the location hole of three layers of duralumin plate is designed at identical post.

9. a kind of forming side of oversize single reflecting surface composite honeycomb sandwich structure panel according to claim 3 Method, it is characterised in that: in step (3): high calculate of nail is completed by following closely high software for calculation；The software have project management, Panel management, the high calculating of nail and data import four modules, and project need to first be established by calculating nail height for the first time, then calculate again in nail height Module is calculated, and the nail height of same project different panels calculates later, then is only needed using the high computing module of nail；First in project Project is established in management module, setting curved surface type is parabolic cylinder, inputs 20000 millimeters of curved surface focal length, panel geometric parameter It is 20000 millimeters × 18000 millimeters, heel teeth type is independent heel teeth, i.e. panel and heel teeth is separately manufactured, and panel piecemeal is 5 rows 7 Column；Again in following closely high computing module, the project name established above is selected, corresponding to the panel that input panel is numbered and to be calculated The considerations of piece behind board cut line coordinate to determine position of the panel in integral panels, be hemispherical, ball at the top of post Head radius selects 20 millimeters, saves parameter after importing nail bed figure, clicks and calculates nail height and start to calculate, by discrete dot matrix dolly set with Then height of the discrete each post at panel theory curved surface is calculated in panel theory SURFACES MATCHING, obtained Enveloping surface, that is, panel theory curved surface that discrete dot matrix dolly set is formed；Calculating finishes outputting standard and follows closely high data file.