基于孔隙控制的车身结构树脂传递模塑成型工艺设计
Design of resin transfer molding process for vehicle body structure based on porosity control

以典型车身结构B柱为研究对象，结合实验与仿真分析研究其树脂传递模塑（RTM）工艺的优化设计方法。研究了通过注射方式的优化控制树脂流动前沿，从而达到降低制件孔隙率和保证制件质量的目的。首先通过自制的变厚度渗透率测试模具获取所选用织物的渗透率，之后通过真空辅助RTM实验与对应模拟仿真进行对比分析来验证所采用仿真方法与渗透率数据的可靠性。最后结合充模周期与孔隙率控制理论对RTM工艺注射口分布及注射方式进行优化设计。结果表明，针对所选定车身结构，优化速率注射方式所获得的制件孔隙率最低，但充模周期较长，而基于双点注射的恒流量注射方式能较好地兼顾充模周期与制件孔隙率的要求。 A typical body structure B-pillar was selected as the research object. Experiment and simulation analysis were used to investigate its optimization design method for resin transfer molding method (RTM) process. The injection mode was optimized by control the resin flow front, which could reduce the porosity and ensure the quality of the part. Firstly, the self-manufactured variable thickness permeability test mold was used to obtain the selected fabric permeability, then the robustness of the adopted simulation method and the obtained permeability data were verified by comparing the vacuum-assisted RTM experiments with the virtual simulations. Finally, combing the filing cycle and the porosity controlling theory, the optimal design of the injection port distribution and injection modes of RTM forming process were investigated. The results show that, for the selected automotive structure, the parts with the injection of optimized injection rate acquire the lowest porosity, but their filling cycles are too long, then the injection of a constant flow rate and two injection ports can better take into account the requirement of both the filling cycle and part porosity. 国家自然科学基金（51405150）；湖南省自然科学基金（2015JJ3052）