CN114425870A

CN114425870A - Motor train unit front end integrated vacuum infusion molding system and molding method

Info

Publication number: CN114425870A
Application number: CN202011084865.2A
Authority: CN
Inventors: 辛美音; 沈海娟; 蔡莺莺; 邓文彬; 王明; 蔡计杰; 张子阳
Original assignee: China Petroleum and Chemical Corp; Sinopec Shanghai Petrochemical Co Ltd
Current assignee: China Petroleum and Chemical Corp; Sinopec Shanghai Petrochemical Co Ltd
Priority date: 2020-10-12
Filing date: 2020-10-12
Publication date: 2022-05-03

Abstract

The invention discloses an integrated vacuum infusion molding system and a molding method for the front end of a motor train unit, wherein the system comprises a molding module, a resin tank, a supply pipe, a recovery pipe, a collecting tank, a vacuum pipe and a vacuum pump, wherein the molding module comprises a mold body matched with the front end of the motor train unit, a sandwich body coated between two layers of reinforcing material layers, demolding cloth, flow guide cloth and a vacuum bag; the forming method comprises the steps of obtaining carbon fiber raw materials, designing a front-end module structure, carrying out simulation analysis, producing and processing a die, forming and curing the composite material and testing product performance. The composite material is molded mainly by a mode of injecting flame-retardant resin in vacuum, and a front-end module molded by adopting an integrated molding die is easy to demould, simple in assembly operation, flexible in product molding, higher in strength and lighter in weight.

Description

Motor train unit front end integrated vacuum infusion molding system and molding method

Technical Field

The invention relates to a bullet train manufacturing technology, in particular to an integrated vacuum infusion molding system and method for the front end of a motor train unit.

Background

The front end structure of the motor train unit is complex, a mode that two halves are separately manufactured and then are in butt joint combination is needed in the traditional technology, and for a high-speed motor train, the mode has poor stability of the whole structure, cannot guarantee stable assembly quality requirements, and is complex to manufacture; and the materials are mostly alloy structures, the mass is heavy, and the cost is high.

Compared with metal materials, the carbon fiber composite material has a plurality of excellent properties, such as light weight, high specific strength, good dimensional stability and excellent chemical stability, so that the application range of the carbon fiber composite material is wider and wider, and the manufacturing process is mature.

Therefore, the process for obtaining the integrally formed front end structure of the high-performance motor train unit by adopting the composite material needs to be developed urgently.

Disclosure of Invention

In order to overcome the defects of the prior art, the invention aims to provide an integrated vacuum infusion molding system and a molding method for the front end of a motor train unit, which can solve the problems and meet the development requirement of the motor train unit of 400 km/h.

The technical scheme is as follows: the purpose of the invention is realized by adopting the following technical scheme.

The utility model provides an integrative vacuum infusion molding system of EMUs front end, the system includes shaping module, resin tank, supply tube, collector, vacuum tube and vacuum pump, the setting of supply tube intercommunication is in between resin tank and the shaping module, collector, vacuum tube and vacuum pump connect gradually, the shaping module includes the mould body of joining in marriage the mould with the EMUs front end, the cladding is at sandwich body, drawing of patterns cloth, water conservancy diversion cloth and the vacuum bag between two-layer reinforcing material layer, and bottom reinforcing material, sandwich body, upper reinforcing material, drawing of patterns cloth and water conservancy diversion cloth are laid in the die cavity of the mould body from bottom to top in proper order, the vacuum bag cladding the upper surface of water conservancy diversion cloth with exceed the upper end setting of bottom reinforcing material, sandwich body, upper reinforcing material, drawing of patterns cloth and water conservancy diversion cloth.

Preferably, the upper end of the flow guide cloth is arranged in a manner of extending to cover the two layers of the reinforcing material layers and the upper end of the sandwich body.

Preferably, the reinforcing material layer is a composite material of glass fiber, carbon fiber or both with high strength and high modulus.

Preferably, the sandwich body is a foam sandwich.

A method for integrally forming a front end module of a motor train unit comprises the following steps:

step 1: obtaining carbon fiber raw materials, testing and analyzing the performance of various raw materials according to technical requirements, selecting carbon fiber materials meeting the requirements, and weaving the carbon fiber materials into a required fiber layer;

step 2: designing the structure of the front-end module, carrying out simulation analysis, carrying out feasibility analysis including simulation stress on the integrated structure of the front-end module, and determining the reliability of the integrally-formed front-end module;

and step 3: the production and processing of the die, namely designing and manufacturing the die according to the integral molding requirement of the front-end module;

and 4, step 4: molding and curing the composite material, namely injecting flame-retardant resin into a mold by using vacuum pressure by adopting a vacuum infusion molding process, heating and curing the resin after the resin is uniformly immersed into the carbon fiber fabric, and drawing the cured composite material product after cooling;

and 5: and (3) testing the product performance, namely testing the product by parameters including strength, impact resistance and vibration impact to ensure that each index meets the requirement.

Compared with the prior art, the invention has the beneficial effects that: the system and the method need to select different carbon fiber composite material molding processes according to the final use and the structural modeling requirements of products. Compared with the traditional front-end module manufacturing process, the integrated forming process for the front-end module of the motor train unit reduces the complexity of the assembling process, is high in manufacturing rate and stable in product, and the contour of the formed product is unified in standard (mold guarantee). In addition, the vertical angle of the upper part of the module is changed into an angle easy to demould, so that demoulding of the product after forming is facilitated, and the production efficiency and the product yield are improved while the product quality is ensured.

Drawings

FIG. 1 is a schematic diagram of an integrated vacuum infusion molding system for the front end of a motor train unit.

In the figure:

100. a molding module; 1. a mold body; 2. a layer of reinforcing material; 3. a core body; 4. demolding the cloth; 5. flow guiding cloth; 6. vacuum bag;

200. a resin tank;

300. a supply pipe;

400. a recovery pipe;

500. a collection tank;

600. a vacuum tube;

700. a vacuum pump.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.

Referring to fig. 1, an integrated vacuum infusion molding system for the front end of a motor train unit comprises a molding module 100, a resin tank 200, a supply pipe 300, a recovery pipe 400, a collection tank 500, a vacuum pipe 600 and a vacuum pump 700.

Connection relation: the supply pipe 300 is connected between the resin tank 200 and the molding module 100, the recovery pipe 400, the collection tank 500, the vacuum pipe 600, and the vacuum pump 700 are connected in sequence.

The forming module 100 comprises a die body 1 matched with a die at the front end of the motor train unit, a sandwich body 3 coated between two layers of reinforcing material layers 2, demolding cloth 4, a flow guide cloth 5 and a vacuum bag 6, wherein a bottom layer reinforcing material, the sandwich body 3, an upper layer reinforcing material, the demolding cloth 4 and the flow guide cloth 5 are sequentially laid in a die cavity of the die body 1 from bottom to top, and the vacuum bag 6 coats the upper surface of the flow guide cloth 5 and is arranged to exceed the upper end surfaces of the bottom layer reinforcing material, the sandwich body 3, the upper layer reinforcing material, the demolding cloth 4 and the flow guide cloth 5.

Furthermore, the upper end of the flow guide cloth 5 is arranged by extending and coating the upper ends of the two layers of the reinforcing material layers 2 and the sandwich body 3.

Furthermore, a die cavity of the die body 1 is provided with a die drawing angle, a vertical surface on one side of a conical nose of a product at the front end of the motor train unit is provided with a 3-degree die drawing angle, and a vertical surface on the bottom side of the product at the front end of the motor train unit is provided with a 1-degree die drawing angle, so that the product can be conveniently demoulded after being molded.

Further, the resin tank 200 supplies flame-retardant resin.

Further, the reinforcing material layer 2 is a woven unidirectional fabric and a multiaxial unidirectional fabric having high strength and high modulus.

Further, the woven unidirectional fabric is 400gsm, and the multiaxial unidirectional fabric is 600 gsm.

In a specific embodiment, the weaving of the carbon fiber dry cloth: the carbon fibers were woven into two sizes of fabrics, the specific process parameters are shown in tables 1 and 2:

TABLE 1400 gsm woven unidirectional fabric weaving process parameters

TABLE 2600 gsm multiaxial unidirectional fabric weaving Process parameters

Further, the reinforcing material layer 2 is a composite material of glass fiber, carbon fiber or both with high strength and high modulus.

Further, the sandwich body 3 is a foam sandwich.

A method for integrally forming a front end module of a motor train unit comprises the following steps.

Step 1: the method comprises the steps of obtaining carbon fiber raw materials, testing and analyzing the performance of various raw materials according to technical requirements, selecting carbon fiber materials meeting the requirements, and weaving the carbon fiber materials into a required fiber layer.

Step 2: the method comprises the steps of front-end module structure design and simulation analysis, wherein feasibility analysis including simulation stress is carried out on an integrated structure of a front-end module, and the reliability of the integrally-formed front-end module is determined.

And step 3: and (4) producing and processing the die, and designing and manufacturing the die according to the integrated molding requirement of the front-end module.

And 4, step 4: and (3) molding and curing the composite material, namely injecting flame-retardant resin into the mold by using a vacuum infusion molding process by using vacuum pressure, heating and curing the resin after the resin is uniformly immersed into the carbon fiber fabric, and drawing the cured composite material product after cooling.

Specifically, the fire-retardant resin is not as good as after pouring into the back inspection, puts into the oven with the mould, carries out thermoforming to the product according to temperature, the atmospheric pressure parameter that front end module shaping control standard set for, pulls out the mould after the shaping time arrives, puts into the cooling platform and carries out the mould cooling, waits to open the mould after the mould cooling and takes out the product.

Further, in step 1, it was determined that carbon fibers of the type SCF35S-12K were used. In step 4, the system is used for vacuum infusion molding, unsaturated flame-retardant resin is pressed into the fiber layer through a pre-laid pipeline by using the pressure generated by vacuum, the resin is soaked with the reinforcing material and finally fills the mold cavity of the whole mold, and after the product is cured, the vacuum bag material is removed, and the required product is obtained from the mold.

The material used by the front-end product of the motor train unit manufactured by the system and the method is the carbon fiber composite material with high strength and high modulus, and meanwhile, the flame retardant effect can be achieved. And the weight of the carbon fiber front-end module is directly reduced by 40% compared with that of the metal module.

The invention relates to an integrally formed flame-retardant high-strength motor train unit front-end module, wherein composite material forming is mainly formed by injecting flame-retardant resin in vacuum, and the invention relates to manufacturing of a mold suitable for integral forming. Compared with the traditional formed front end module, the front end module formed by adopting the integrated forming die has the advantages of easy demoulding, simple assembly operation, flexible product modeling, higher strength and lighter weight.

Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.

Claims

1. An integrated vacuum infusion molding system for the front end of an EMU, the system comprising a molding module (100), a resin tank (200), a supply pipe (300), a recovery pipe (400), a collection tank (500), and a vacuum pipe (600) and a vacuum pump (700), the supply pipe (300) is communicated between the resin tank (200) and the forming module (100), the forming module (100), the recovery pipe (400), the collecting The tank (500), the vacuum tube (600) and the vacuum pump (700) are connected in sequence, and it is characterized in that: the forming module (100) comprises a mold body (1) that is matched with the front end of the EMU, and is covered with two layers of reinforcing materials. Sandwich body (3), release cloth (4), diversion cloth (5) and vacuum bag (6) between layers (2), bottom reinforcement material, sandwich body (3), upper layer reinforcement material, release cloth (4), and the guide cloth (5) are sequentially laid in the mold cavity of the mold body (1) from bottom to top, and the vacuum bag (6) covers the upper surface of the guide cloth (5) and exceeds the upper surface of the guide cloth (5). The bottom layer reinforcing material, the sandwich body (3), the upper layer reinforcing material, the mold release cloth (4), and the upper end surface of the guide cloth (5) are arranged.

2 . The system according to claim 1 , wherein the upper end of the guide cloth ( 5 ) is epitaxially coated on the upper end of the two reinforcing material layers ( 2 ) and the sandwich body ( 3 ). 3 .

3. The system according to claim 1, characterized in that: the mold body (1) cavity is set with a draft angle, and a 3° draft angle is made on the vertical surface of the tapered nose side of the front end product of the EMU, Make a draft angle of 1° on the vertical surface of the bottom side of the front-end product of the EMU to facilitate the demoulding of the product after molding.

4. The system according to claim 1, wherein the resin tank (200) is supplied with flame retardant resin.

5. The system according to claim 1, wherein the reinforcing material layer (2) is a woven unidirectional fabric and a multiaxial unidirectional fabric with high strength and high modulus.

6. The system of claim 5, wherein the woven unidirectional fabric is 400 gsm and the multiaxial unidirectional fabric is 600 gsm.

7. The system according to claim 1 or 5, characterized in that: the reinforcing material layer (2) is a composite material of glass fiber, carbon fiber or both with high strength and high modulus.

8. The system according to claim 1, wherein the sandwich body (3) is a foam sandwich.

9. A method for forming an integrated front-end module of an EMU, characterized in that the method comprises the following steps:

Step 1: Obtain carbon fiber raw materials, test and analyze the performance of various raw materials according to technical requirements, select carbon fiber materials that meet the requirements, and weave them into required fiber layers;

Step 2: structural design and simulation analysis of the front-end module, feasibility analysis of the integrated structure of the front-end module including simulated stress, and determination of the reliability of the integrally formed front-end module;

Step 3: Mold production and processing, mold design and manufacture according to the requirements of front-end module integrated molding;

Step 4: forming and curing the composite material, adopting the vacuum infusion forming process, injecting flame retardant resin into the mold by using vacuum pressure, heating and curing after the resin is evenly immersed in the carbon fiber fabric, and pulling out the cured composite material product after cooling;

Step 5: Product performance test, test the product including strength, impact resistance, vibration and impact parameters to ensure that each index meets the requirements.

10. The method according to claim 9, wherein: in step 1, it is determined to use SCF35S-12K type carbon fiber; in step 4, the system according to any one of claims 1-8 is used for vacuum perfusion The unsaturated flame retardant resin is pressed into the fiber layer through the pre-laid pipeline by the pressure generated by the vacuum, so that the resin infiltrates the reinforcing material and finally fills the cavity of the entire mold. After the product is cured, the vacuum bag is removed. Material, get the desired product from the mold.