Abstract
The rapid and low-cost manufacturing of continuous Carbon Fiber Reinforced Polymer (CFRP) composites using 3D printing technology is a hot topic in the field of composite materials’ research. Due to the continuity and infusibility of the long carbon fiber, a series of problems such as loosening of fiber, breakage, and nozzle clogging occurred in the printing process, which result in poor surface quality and performance in the printed product. This paper aims to solve these problems based on the researches and optimizations of three-dimensional printing technology for continuous CFRP composite components. Firstly, the coupling mechanism of continuous fiber and resin polymer in the flow path of nozzle is analyzed, the finite element simulation models of flow field and temperature field of CFRP three-dimensional printing are established by using ANSYS CFX software, and the coupling characteristics and interface performance in the printing process are studied. Then, based on the results of simulation analysis, a modification method of the surface coating film is applied, and a special modification solution is configured to modify the surface of the carbon fiber so as to increase its strength and bondability with the molten resin. Finally, the mechanical structure of the three-dimensional printing system of continuous CFRP components is designed to achieve the synchronization of printing and fiber modification. Considering the continuity of continuous carbon fiber, this paper proposed a new method of printing path design called “unicursal” for continuous CFRP parts, that is, when designing and planning a three-dimensional print path, it ensured that there is no interruption in the printing process, so as to achieve carbon fiber continuity in composite parts. The reliability and superiority of the printing system designed in this paper are confirmed by printing of the composite parts.
Highlights
Composite material is a new type of material synthesized from two or more materials of different properties by physical or chemical methods
The manufacturing process of the traditional Continuous Carbon Fiber Reinforced Polymer (CFRP) component mainly includes three steps: First, the prepreg is prepared by a deposition method or a dipping method; a simple-shaped composite material part is manufactured through a process of laying, pultrusion, and winding; continuous CFRP members are prepared by machining assembly, cementation and other processes[1]
In the 3D printing process of continuous fiber reinforced resin composites,because of the continuous carbon fiber does not melt at a high temperature and its own strength is insufficient, it often causes the problems of continuous fiber breakage and fiber blocking of the nozzle in the three-dimensional printing, resulting in the result that the surface of the product is not smooth, the precision is low, and the component cannot be formed[46]
Summary
Composite material is a new type of material synthesized from two or more materials of different properties by physical or chemical methods. Compared with traditional manufacturing processes, 3D printing technology has the advantages of low cost, high material utilization, and simple process[2]. Manufacture of composite materials has important engineering significance for promoting the cost-effective manufacture of continuous fiber-reinforced resin-based composite products. In the 3D printing process of continuous fiber reinforced resin composites,because of the continuous carbon fiber does not melt at a high temperature and its own strength is insufficient, it often causes the problems of continuous fiber breakage and fiber blocking of the nozzle in the three-dimensional printing, resulting in the result that the surface of the product is not smooth, the precision is low, and the component cannot be formed[46]. This article mainly focuses on the above issues, researches and optimizes the three-dimensional printing technology of continuous CFRP composite components. Taking into account the continuity of continuous carbon fiber, this article proposes a new type of "unicursal" print path for continuous CFRP components, that is, when planning a three-dimensional print path, it is allowed to have no interruption in the printing process, so as to ensure the composite Continuity of Carbon Fibers in Molded Parts[8]. the three-dimensional printing of continuous CFRP components proves the effectiveness of the system designed in this paper
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