技术领域technical field
本发明属于FSAE赛车上独立悬架系统中碳纤维双横臂的胶连接工艺，具体涉及一种基于超声波振动下辅助碳纤维管与铝接头胶连接的粘胶工艺与超声波振动辅助粘胶装置。The invention belongs to the glue connection process of carbon fiber double wishbone in the independent suspension system of the FSAE racing car, and specifically relates to a glue connection process based on ultrasonic vibration to assist the glue connection of carbon fiber tubes and aluminum joints and an ultrasonic vibration auxiliary glue device.
背景技术Background technique
随着我国汽车行业的迅速发展和人民生活品质的提高，各式各样的赛车运动相继产生，赛车文化逐渐进入人们的生活。2010年，中国举办了首届大学生方程式(FSAE)赛车比赛，很多高校相继展开了对于FSAE赛车的研究、制造与调试。对于方程式赛车而言，整车重量是衡量整车设计水平的一个重要因素。而FSAE赛车为了控制整车重量，在很多部件中开始应用碳纤维，一些高设计水平赛车的整备质量可以低到150kg左右。With the rapid development of my country's automobile industry and the improvement of people's quality of life, various racing sports have emerged one after another, and racing culture has gradually entered people's lives. In 2010, China held the first Student Formula (FSAE) racing competition, and many colleges and universities successively launched the research, manufacture and debugging of FSAE racing cars. For formula racing cars, the weight of the whole vehicle is an important factor to measure the design level of the whole vehicle. In order to control the weight of the whole car, the FSAE racing car has begun to use carbon fiber in many parts. The curb weight of some high-level racing cars can be as low as 150kg.
碳纤维复合材料是由碳纤维与基体材料通过某种复合方式被组合而成的新型材料，碳纤维复合材料不仅保持了原材料的特点，还具有单一材料所没有的特性：Carbon fiber composite material is a new type of material composed of carbon fiber and matrix material in a certain way. Carbon fiber composite material not only maintains the characteristics of raw materials, but also has characteristics that a single material does not have:
(1)较高比模量和比强度，在同等受力条件下，使用碳纤维复合材料可以大大地减少重量，尤其对于汽车而言，减少重量就是降低燃油经济性，符合现在国家的汽车三大主题。而对于赛车，整车质量更是非常重要，悬架系统中的杆件就很适合使用碳纤维材料。(1) High specific modulus and specific strength. Under the same stress conditions, the use of carbon fiber composite materials can greatly reduce the weight. Especially for automobiles, reducing weight means reducing fuel economy, which is in line with the current national three major automobiles. theme. For racing cars, the quality of the vehicle is very important, and the rods in the suspension system are very suitable for using carbon fiber materials.
(2)很好的材料柔韧度。(2) Good material flexibility.
(3)优异的减震性。(3) Excellent shock absorption.
(4)较好的耐疲劳性，在同等拉伸强度下，金属材料抗疲劳强度只有碳纤维复合材料50％左右。(4) Good fatigue resistance. Under the same tensile strength, the fatigue resistance of metal materials is only about 50% of that of carbon fiber composite materials.
(5)成型工艺性好。(5) The molding process is good.
(6)破损安全性好。(6) Good damage safety.
现在，很多汽车制造商青睐碳纤维复合材料，很多大型的汽车厂商生产的部分高档及豪华轿车，碳纤维复合材料己经被采用了。碳纤维材料在汽车上的应用可以使汽车的轻量化取得长足进步。尽管与汽车上使用的其它材料相比碳纤维复合材料较昂贵，但由于在轻量化设计方面的巨大潜力，汽车制造厂商们仍然对他们兴趣不减。近年来，在批量生产汽车零件上一些汽车制造厂商己开始采用碳纤维增强复合材料。Now, many car manufacturers favor carbon fiber composite materials, and some high-end and luxury cars produced by many large car manufacturers, carbon fiber composite materials have been adopted. The application of carbon fiber materials in automobiles can make great progress in the lightweight of automobiles. Although carbon fiber composites are expensive compared to other materials used in cars, carmakers are still interested in them due to their great potential for lightweight design. In recent years, some automobile manufacturers have begun to use carbon fiber reinforced composite materials in the mass production of automobile parts.
悬架对于动力学的重要性体现在其运动特性及其对从轮胎传递到底盘的力和力矩的响应。对于方程式赛车的整车设计，悬架性能显然是影响整车操纵稳定性和平顺性的重要因素，故悬架系统的设计在整车设计中占据着举足轻重的地位。将碳纤维成功运用到悬架系统上下叉臂中后，钢制叉臂为4.23kg，而碳纤维叉臂只有1.78kg，减重比例达到57％，仅仅一个上下叉臂为赛车成功减重2.45kg。The importance of the suspension to dynamics is reflected in its kinematic characteristics and its response to the forces and moments transmitted from the tires to the chassis. For the vehicle design of a formula car, the suspension performance is obviously an important factor affecting the handling stability and smoothness of the vehicle, so the design of the suspension system occupies a pivotal position in the vehicle design. After successfully applying carbon fiber to the upper and lower wishbone of the suspension system, the steel wishbone is 4.23kg, while the carbon fiber wishbone is only 1.78kg, and the weight reduction ratio reaches 57%. Only one upper and lower wishbone successfully reduces the weight of the car by 2.45kg.
但是选择碳纤维管为独立悬架系统中的双横臂的材料之后，随之出现一个重要的问题，便是碳纤维与金属制件的连接。使用胶粘剂将需要胶接的两个件粘成一个件的方法称为胶连接。胶连接对纤维破坏最小，产生的应力集中小；最后粘成一个件的总质量小；做出的表面非常光滑、制作工艺很简便、制作加工成本比较低，并且比较能抵抗腐蚀，产生的永久变形小。但是，较难控制的是胶连接的质量，如胶连接传递很高载荷，则受力会不可靠。However, after carbon fiber tubes are selected as the material for the double wishbone in the independent suspension system, an important problem arises, which is the connection between carbon fiber and metal parts. The method of using adhesive to bond two parts that need to be glued into one is called glue connection. The glue connection has the least damage to the fiber, and the stress concentration generated is small; the total mass of the final bonded piece is small; the surface is very smooth, the manufacturing process is very simple, the manufacturing process cost is relatively low, and it is relatively resistant to corrosion, resulting in permanent Small deformation. However, it is more difficult to control the quality of the glue connection. If the glue connection transmits a high load, the force will be unreliable.
目前，国内对FSAE碳纤维悬架粘接问题的研究主要是以哈尔滨工业大学为代表的通过改变粘胶剂的类型、粘接的长度、粘接间隙、表面处理等因素进行改善与研究。虽然取得了一定的进步与改进，但是由于在碳纤维管与铝接头的粘胶过程中，人为因素的影响非常大。经过重复性试验后进行数据分析与处理，便发现各个试件的粘接强度的差异性(波动)很大，并且经常会出现粘接强度不符合要求的案例。而FSAE赛车为了安全，绝对不允许出现碳纤维悬架粘接强度不足的概率，因此，不少大学的FSAE赛车转而使用传统的钢制焊接的悬架横臂。At present, domestic research on FSAE carbon fiber suspension bonding is mainly carried out by changing the type of adhesive, bonding length, bonding gap, surface treatment and other factors represented by Harbin Institute of Technology. Although some progress and improvements have been made, the influence of human factors is very large in the process of gluing carbon fiber tubes and aluminum joints. After repeated tests and data analysis and processing, it was found that the difference (fluctuation) of the bonding strength of each test piece is very large, and there are often cases where the bonding strength does not meet the requirements. For the sake of safety, the FSAE racing car absolutely does not allow the possibility of insufficient bonding strength of the carbon fiber suspension. Therefore, many university FSAE racing cars use traditional steel welded suspension arms.
发明内容Contents of the invention
本发明所要解决的技术问题是：提供一种超声波振动辅助碳纤维悬架横臂胶连接方法及装置，以克服上述现有技术存在的缺陷。The technical problem to be solved by the present invention is to provide an ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection method and device to overcome the above-mentioned defects in the prior art.
本发明解决其技术问题采用的技术方案是：The technical scheme that the present invention solves its technical problem adopts is:
本发明提供的超声波振动辅助碳纤维悬架横臂胶连接装置，其包括气泵、气缸、超声波发生器、超声波换能器、超声波振动工具头，以及能将碳纤维管与铝接头定位的工件夹具，其中：超声波换能器通过变幅杆与超声波振动工具头的一端相连，超声波振动工具头的另一端通过圆柱导轨与气缸活塞相连。The ultrasonic vibration-assisted cross-arm adhesive connection device for carbon fiber suspension provided by the present invention includes an air pump, a cylinder, an ultrasonic generator, an ultrasonic transducer, an ultrasonic vibration tool head, and a workpiece fixture capable of positioning the carbon fiber tube and the aluminum joint, wherein : The ultrasonic transducer is connected with one end of the ultrasonic vibration tool head through the horn, and the other end of the ultrasonic vibration tool head is connected with the cylinder piston through the cylindrical guide rail.
所述超声振动工具头，其上端设有螺纹孔，该螺纹孔与变幅杆的下端螺纹连接，变幅杆的另一端与超声波换能器相连。The upper end of the ultrasonic vibration tool head is provided with a threaded hole, the threaded hole is threadedly connected with the lower end of the horn, and the other end of the horn is connected with the ultrasonic transducer.
所述超声波振动工具头的头部设有直径为26-30mm的圆弧槽，该圆弧槽所在圆的圆心超出槽口端面5-7mm。The head of the ultrasonic vibrating tool head is provided with an arc groove with a diameter of 26-30mm, and the center of the circle where the arc groove is located exceeds the end face of the notch by 5-7mm.
所述变幅杆为纵振圆锥式变幅杆，主要用于将其机械振动的质点位移或速度放大，并将超声能量集中在较小的面积上，同时用于调整超声波换能器与超声波振动工具头之间的负载匹配，减小谐振阻抗。The horn is a longitudinal vibration conical horn, which is mainly used to amplify the particle displacement or velocity of its mechanical vibration, concentrate the ultrasonic energy on a small area, and at the same time adjust the ultrasonic transducer and ultrasonic Load matching between vibrating tool heads reduces resonance impedance.
所述工件夹具由位于超声波实验台上的定位滑槽，以及均设有26-30mm的圆弧槽的第一定位滑块、第二定位滑块、夹紧元件、定位凸台组成；所述圆弧槽所在圆的圆心均超出槽口端面5-7mm，以通过调整装在有螺纹孔的定位凸台上的紧固螺钉来定位、夹紧不同直径的碳纤维管。The workpiece fixture is composed of a positioning chute positioned on the ultrasonic test bench, and a first positioning slide block, a second positioning slide block, a clamping element, and a positioning boss all provided with an arc groove of 26-30mm; The center of the circle where the arc groove is located exceeds the end face of the notch by 5-7mm, so as to locate and clamp carbon fiber tubes of different diameters by adjusting the fastening screws mounted on the positioning bosses with threaded holes.
所述第一定位滑块、第二定位滑块和定位凸台，其在碳纤维管轴向的长度均为50—60mm，且都通过螺栓与定位滑槽相连。The first positioning slider, the second positioning slider and the positioning boss all have a length of 50-60mm in the axial direction of the carbon fiber tube, and are all connected to the positioning chute through bolts.
本发明提供的超声波振动辅助碳纤维悬架横臂胶连接工艺，是利用上述超声波振动辅助碳纤维悬架横臂胶连接装置实现的，该工艺包括以下步骤：The ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection process provided by the present invention is realized by using the above-mentioned ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection device. The process includes the following steps:
1)调整工件夹具在超声波工作台上的安装位置、并用螺栓将其固定，同时确保超声波工具头的初始位置与工件夹具相对位置满足试工件有效粘接部位对中要求；1) Adjust the installation position of the workpiece fixture on the ultrasonic workbench and fix it with bolts, and at the same time ensure that the initial position of the ultrasonic tool head and the relative position of the workpiece fixture meet the alignment requirements of the effective bonding part of the test workpiece;
2)使用具有乳化作用的去污剂将加工好的铝接头和碳纤维管表面污渍去除，再用清水冲洗干净；2) Use an emulsifying detergent to remove the stains on the surface of the processed aluminum joints and carbon fiber tubes, and then rinse them with clean water;
3)用丙酮将碳纤维管内表面和铝接头的粘胶部位清洗干净；3) Clean the inner surface of the carbon fiber tube and the viscose parts of the aluminum joint with acetone;
4)用胶枪配合混合嘴将DP460胶水分别在碳纤维管内表面和铝接头的粘接部位涂抹均匀；4) Use a glue gun with a mixing nozzle to apply DP460 glue evenly on the inner surface of the carbon fiber tube and the bonding part of the aluminum joint;
5)将铝接头缓慢旋进碳纤维管，然后将其整体放置在工件夹具上定位，并用紧固螺钉将其夹紧、固定；5) Slowly screw the aluminum joint into the carbon fiber tube, then place it on the workpiece fixture for positioning, and clamp and fix it with fastening screws;
6)调节气缸的压力，使超声波工具头以设定压力压至碳纤维管粘接段外表面；6) Adjust the pressure of the cylinder so that the ultrasonic tool head is pressed to the outer surface of the carbon fiber tube bonding section at the set pressure;
7)开启超声波发生器，调节其输出频率为20kHz，振幅为4-6微米，对碳纤维管外壁施加工作2s，间隔2s的脉冲振动，共进行≥30s；然后将碳纤维管与铝接头整体从工件夹具中取出；7) Turn on the ultrasonic generator, adjust its output frequency to 20kHz, and the amplitude to 4-6 microns, and apply pulse vibrations on the outer wall of the carbon fiber tube for 2s with an interval of 2s for a total of ≥30s; then remove the carbon fiber tube and the aluminum joint from the workpiece as a whole out of the fixture;
8)将粘接好的碳纤维悬架横臂在常温下放置≥2小时，直至完全固化。8) Place the bonded carbon fiber suspension arm at room temperature for ≥ 2 hours until it is completely cured.
上述步骤1)中，所述的超声波工具头的初始位置应处于铝接头有效粘接部位的中间位置的正上方。In the above step 1), the initial position of the ultrasonic tool head should be directly above the middle position of the effective bonding part of the aluminum joint.
上述步骤4)中，应保证胶层的度厚比碳纤维管和铝接头之间的配合间隙大0.1—0.3mm，同时须将碳纤维管内表面和铝接头粘接部位的胶水涂抹均匀。In the above step 4), the thickness of the glue layer should be ensured to be 0.1-0.3mm larger than the fitting gap between the carbon fiber tube and the aluminum joint, and the glue on the inner surface of the carbon fiber tube and the bonding part of the aluminum joint must be evenly applied.
上述步骤6)中，气缸压力应调整为0.3—0.5MPa，超声波工具头的下降行程应比其初始位置时凹槽底端与定位的碳纤维管外表面的最短距离≥0.2—0.5mm。In the above step 6), the cylinder pressure should be adjusted to 0.3-0.5MPa, and the descending stroke of the ultrasonic tool head should be greater than or equal to 0.2-0.5mm than the shortest distance between the bottom of the groove and the outer surface of the positioned carbon fiber tube at its initial position.
本发明与现有技术相比，主要有以下的优点：Compared with the prior art, the present invention mainly has the following advantages:
1.采用全新的工艺——基于超声波振动辅助碳纤维与铝接头的胶连接，显著增强碳纤维管与铝接头的粘接强度，同时改善原始粘胶工艺在重复性试验中出现粘接强度不稳定、差异性显著、试验数据波动大以及出现试件不合格的问题。1. Adopting a brand-new technology-based on the ultrasonic vibration-assisted glue connection between carbon fiber and aluminum joints, which significantly enhances the bonding strength between carbon fiber tubes and aluminum joints, and at the same time improves the original viscose process. The bonding strength is unstable, There are significant differences, large fluctuations in test data, and problems with unqualified test pieces.
2.该超声波辅助粘接的工艺原理是利用超声波振动辅助碳纤维悬架横臂胶接的粘胶装置，通过设置气缸压力、超声波振动加载位置、振动时间等因素，促进胶水在碳纤维管与铝接头缝隙之间的流动，使胶水在缝隙中的分布均匀化，明显提升碳纤维与铝接头之间的粘接强度，从而形成一套完整、稳定、可靠的碳纤维悬架的胶连接工艺。2. The process principle of ultrasonic assisted bonding is to use ultrasonic vibration to assist the adhesive device of carbon fiber suspension cross arm bonding. By setting the cylinder pressure, ultrasonic vibration loading position, vibration time and other factors, the glue is promoted on the carbon fiber tube and the aluminum joint. The flow between the gaps makes the distribution of glue uniform in the gaps, significantly improving the bonding strength between carbon fiber and aluminum joints, thus forming a complete, stable and reliable carbon fiber suspension glue connection process.
3.采用全新的思维解决碳纤维悬架横臂的粘接问题——目前，国内大多数FSAE车队仍然使用钢制焊接悬架的主要原因就是完全人工操作、人工干预进行碳纤维悬架粘接时粘接强度很不稳定，由于无法得到参数化或者自动化的控制，因此，没有人可以保证所粘接的碳纤维悬架100％合格。采用超声波振动辅助碳纤维悬架进行粘接碳纤维悬架时，可以通过改变超声波振动的压力、振动时间、振动位置等参数进行研究，从而可以找到超声波振动辅助粘接的最佳条件，并且可以实现对碳纤维悬架横臂粘接过程的参数化控制，从而，使得粘接处理过的碳纤维悬架的可靠性得到有效的保证。同时，也为碳纤维悬架在FSAE赛车上的继续使用提供保障。3. Use brand-new thinking to solve the bonding problem of the carbon fiber suspension cross arm-at present, the main reason why most domestic FSAE teams still use steel welded suspension is that it is completely manual operation and manual intervention for carbon fiber suspension bonding. The bonding strength is very unstable, and no one can guarantee that the bonded carbon fiber suspension is 100% qualified because it cannot be controlled by parameterization or automation. When using ultrasonic vibration-assisted carbon fiber suspension to bond carbon fiber suspension, it can be studied by changing the parameters of ultrasonic vibration pressure, vibration time, vibration position, etc., so that the best conditions for ultrasonic vibration-assisted bonding can be found, and it can be realized. The parameterized control of the bonding process of the cross arm of the carbon fiber suspension effectively guarantees the reliability of the bonded carbon fiber suspension. At the same time, it also provides guarantee for the continued use of carbon fiber suspension on FSAE racing cars.
4.该超声波振动辅助碳纤维管与铝接头的粘胶装置具有比较广泛的适用性——通过对定位滑块元件、夹紧元件和超声波振动工具头等的圆弧槽特殊设计、加工，实现了本发明中涉及的超声波振动辅助粘胶装置可以实现对直径分布在16—28mm的碳纤维悬架横臂胶连接，而国内所有高校的FSAE赛车的悬架横臂尺寸基本都包括在这一尺寸范围之内；定位滑块元件在碳纤维管轴向的长度较小，从而可以通过改变滑块元件的数量来实现超声波振动辅助粘胶时对不同长度的赛车横臂的定位、夹紧。4. The gluing device of the ultrasonic vibration-assisted carbon fiber tube and the aluminum joint has a wide range of applicability - through the special design and processing of the arc grooves of the positioning slider components, clamping components and ultrasonic vibration tool heads, etc., this is achieved. The ultrasonic vibration-assisted gluing device involved in the invention can realize the glue connection of carbon fiber suspension cross arms with a diameter distribution of 16-28mm, and the suspension cross arms of all FSAE racing cars in domestic colleges and universities are basically included in this size range. Inside; the length of the positioning slider element in the axial direction of the carbon fiber tube is small, so that the positioning and clamping of the cross-arm of the racing car with different lengths can be realized when ultrasonic vibration is assisted in gluing by changing the number of slider elements.
附图说明Description of drawings
图1为超声波工作台的结构示意图。Figure 1 is a schematic diagram of the structure of the ultrasonic workbench.
图2为本发明超声波对碳纤维加载振动辅助粘接的轴测图。Fig. 2 is an axonometric view of ultrasonic loading and vibration-assisted bonding of carbon fibers according to the present invention.
图3为图2的俯视图。FIG. 3 is a top view of FIG. 2 .
图4为碳纤维管使用紧固螺钉夹紧状态的局部放大图。Fig. 4 is a partially enlarged view of a state where a carbon fiber tube is clamped by a fastening screw.
图5为超声波工具头对碳纤维加载振动状态的局部放大图。Fig. 5 is a partial enlarged view of the vibration state of the ultrasonic tool head on the carbon fiber.
图6为超声波工具头的振动曲线。Fig. 6 is the vibration curve of the ultrasonic tool head.
图7是经过重复试验得到的不同粘胶工艺下碳纤维悬架的粘接强度均值对比。Figure 7 is a comparison of the average bonding strength of carbon fiber suspensions under different viscose processes obtained through repeated tests.
图8是经过重复试验得到的不同粘胶工艺下碳纤维悬架的粘接强度方差对比。Figure 8 is a comparison of the variance of the bonding strength of the carbon fiber suspension under different viscose processes obtained through repeated tests.
图中：1.气泵；2.气缸；3.圆柱导轨；4.变幅杆；5.超声波实验台；6.气缸活塞；7.超声波发生器；8.超声波换能器；9.超声波振动工具头；10.第一定位滑块；11.螺纹孔；12.铝接头；13.定位滑槽；14.碳纤维管；15.第二定位滑块；16.紧固螺钉；17.夹紧元件；18.有螺纹孔的定位凸台；19.螺栓。In the figure: 1. Air pump; 2. Cylinder; 3. Cylindrical guide rail; 4. Horn; 5. Ultrasonic test bench; 6. Cylinder piston; 7. Ultrasonic generator; 8. Ultrasonic transducer; 9. Ultrasonic vibration Tool head; 10. First positioning slider; 11. Threaded hole; 12. Aluminum joint; 13. Positioning chute; 14. Carbon fiber tube; 15. Second positioning slider; 16. Fastening screw; 17. Clamping Components; 18. Locating bosses with threaded holes; 19. Bolts.
具体实施方式detailed description
下面结合实施实例及附图对本发明创新的具体实施方式作进一步说明。The innovative specific implementation of the present invention will be further described below in conjunction with the implementation examples and the accompanying drawings.
本发明提供的超声波振动辅助碳纤维悬架横臂胶连接工艺，是通过超声波振动辅助碳纤维悬架横臂胶连接装置实现的，该装置的结构如图1至图5所示，主要由气泵1、气缸2、超声波发生器7、超声波换能器8、超声波振动工具头9和工件夹具组成，其中：超声波发生器7把市电转换成与超声波换能器8相匹配的高频交流电信号，驱动超声波换能器8工作；超声波换能器8将高频交流电信号转变为超声波振动，变幅杆4将机械振动幅值放大后传送到超声波振动工具头9。在工件夹具——定位滑槽13和第一定位滑块10、第二定位滑块15、有螺纹孔的定位凸台18组合作用下，将碳纤维管14与铝接头12定位，然后，夹紧元件17通过螺栓以及超声波振动工具头9下降与碳纤维管14接触压紧，将碳纤维管14径向固定。The ultrasonic vibration-assisted cross-arm glue connection process of the carbon fiber suspension provided by the present invention is realized through the ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection device. The cylinder 2, the ultrasonic generator 7, the ultrasonic transducer 8, the ultrasonic vibration tool head 9 and the workpiece fixture, wherein: the ultrasonic generator 7 converts the commercial power into a high-frequency alternating current signal matched with the ultrasonic transducer 8, Drive the ultrasonic transducer 8 to work; the ultrasonic transducer 8 converts the high-frequency AC signal into ultrasonic vibration, and the horn 4 amplifies the mechanical vibration amplitude and transmits it to the ultrasonic vibration tool head 9 . Under the combined action of the workpiece fixture—the positioning chute 13 and the first positioning slider 10, the second positioning slider 15, and the positioning boss 18 with threaded holes, the carbon fiber tube 14 and the aluminum joint 12 are positioned, and then clamped The element 17 is lowered by the bolt and the ultrasonic vibration tool head 9 to contact and press the carbon fiber tube 14 to fix the carbon fiber tube 14 radially.
所述超声振动工具头9采用航空铝合金加工而成，其上端设有螺纹孔11，该螺纹孔11与变幅杆4的下端螺纹连接，变幅杆4的另一端与超声波换能器8相连。The ultrasonic vibration tool head 9 is processed by aviation aluminum alloy, and its upper end is provided with a threaded hole 11, which is threadedly connected with the lower end of the horn 4, and the other end of the horn 4 is connected with the ultrasonic transducer 8 connected.
所述定位滑槽13保持水平，表面平整，稳定可靠，并且固定在超声波实验台5上。The positioning chute 13 is kept horizontal, has a flat surface, is stable and reliable, and is fixed on the ultrasonic test bench 5 .
所述变幅杆4为纵振圆锥式变幅杆，主要材质为45号钢制成，主要用于将机械振动的质点位移或速度放大，并将超声能量集中在较小的面积上，同时用于调整超声波换能器8与超声波振动工具头9之间的负载匹配，减小谐振阻抗。The horn 4 is a longitudinal vibration conical horn, the main material is No. 45 steel, it is mainly used to amplify the particle displacement or velocity of mechanical vibration, and concentrate the ultrasonic energy on a small area. It is used to adjust the load matching between the ultrasonic transducer 8 and the ultrasonic vibrating tool head 9 to reduce the resonance impedance.
所述超声波发生器7额定输出频率为20KHz，功率为1800瓦。The rated output frequency of the ultrasonic generator 7 is 20KHz, and the power is 1800 watts.
所述超声波换能器8为压电式，采用明和20KHz超声波换能器。The ultrasonic transducer 8 is a piezoelectric type, using Minghe 20KHz ultrasonic transducer.
所述气缸2通过管道与气泵1相连，用于储存一定量的气体并通过气体对气缸活塞6做功实现超声振动工具头9的上下移动，调节气缸2的气压值可以改变超声波振动工具头9的预压紧力，气缸2的下部通过气缸活塞6密封，气缸活塞6通过圆柱导轨3与超声波振动工具头9连接，当需要下压超声波振动工具头9时，打开气泵1的开关，使气缸2中气体对气缸活塞6做功，并通过圆柱导轨3将运动传递到超声振动工具头9，使之向下移动，可以通过调节限位螺母位置改变超声波振动工具头9的下移量；当需要上移超声波振动工具头9时，调节开关改变气缸进气方向，气缸2中气体对气缸活塞6做负功，超声波振动工具头9跟随气缸活塞6上移到初始位置。The cylinder 2 is connected to the air pump 1 through a pipeline, and is used to store a certain amount of gas and perform work on the cylinder piston 6 to move the ultrasonic vibration tool head 9 up and down. Adjusting the air pressure value of the cylinder 2 can change the ultrasonic vibration tool head 9. Pre-compression force, the lower part of the cylinder 2 is sealed by the cylinder piston 6, and the cylinder piston 6 is connected to the ultrasonic vibration tool head 9 through the cylindrical guide rail 3. When the ultrasonic vibration tool head 9 needs to be pressed down, the switch of the air pump 1 is turned on to make the cylinder 2 The gas in the cylinder acts on the cylinder piston 6, and transmits the motion to the ultrasonic vibration tool head 9 through the cylindrical guide rail 3 to make it move downward. The downward movement of the ultrasonic vibration tool head 9 can be changed by adjusting the position of the limit nut; When moving the ultrasonic vibration tool head 9, adjust the switch to change the air intake direction of the cylinder, the gas in the cylinder 2 does negative work on the cylinder piston 6, and the ultrasonic vibration tool head 9 moves up to the initial position following the cylinder piston 6.
所述气泵1在启动后进行泵气，并将所泵气体压缩，使气体压强达到设定压强值，当压强低于设定值(例如0.1MPa)后，气泵1会自动泵气，使压强回升到设定值。The air pump 1 pumps air after starting, and compresses the pumped gas to make the gas pressure reach the set pressure value. When the pressure is lower than the set value (such as 0.1MPa), the air pump 1 will automatically pump the air to make the pressure return to the set value.
所述工件夹具由位于超声波实验台5上的定位滑槽13，以及第一定位滑块10、第二定位滑块15、夹紧元件17、有螺纹孔的定位凸台18组成，其中：第一定位滑块10、第二定位滑块15、定位凸台18与夹紧元件17中直径28mm的圆弧槽均为线切割加工而成，并且各个圆弧槽所在圆的圆心均超出端面6mm，因此可以通过调整装在有螺纹孔的定位凸台18上的紧固螺钉16来定位、夹紧不同直径的碳纤维管14，从而保证了该夹具适用于直径分布在16—28mm的碳纤维悬架横臂的超声波振动辅助胶连接。The workpiece fixture is composed of a positioning chute 13 on the ultrasonic test bench 5, a first positioning slider 10, a second positioning slider 15, a clamping element 17, and a positioning boss 18 with threaded holes, wherein: the first The first positioning slider 10, the second positioning slider 15, the positioning boss 18 and the circular arc groove with a diameter of 28 mm in the clamping element 17 are all processed by wire cutting, and the center of the circle where each circular arc groove is located exceeds the end surface by 6 mm. Therefore, carbon fiber tubes 14 with different diameters can be positioned and clamped by adjusting the fastening screws 16 mounted on the positioning boss 18 with threaded holes, thus ensuring that the clamp is suitable for carbon fiber suspensions with diameters ranging from 16 to 28 mm Ultrasonic vibration of the cross-arm assists glue connection.
所述第一定位滑块10、第二定位滑块15和定位凸台18，其分别通过螺栓19与定位滑槽13相连。这三个部件在碳纤维管14轴向的长度均在50—60mm左右，从而可以通过改变定位滑块的数量来满足不同长度的碳纤维悬架横臂的超声波振动辅助胶连接。The first positioning slider 10 , the second positioning slider 15 and the positioning boss 18 are respectively connected to the positioning slide groove 13 through bolts 19 . The axial lengths of these three components in the carbon fiber tube 14 are all about 50-60 mm, so that the ultrasonic vibration-assisted glue connection of carbon fiber suspension cross arms of different lengths can be satisfied by changing the number of positioning sliders.
所述超声波振动工具头9的圆弧槽直径为28mm，且所在圆的圆心超出端面6mm，从而保证了利用一个超声波振动工具头可以实现直径分布在16—28mm的碳纤维悬架横臂的超声波振动辅助胶连接。The diameter of the arc groove of the ultrasonic vibration tool head 9 is 28 mm, and the center of the circle is 6 mm beyond the end face, thereby ensuring that the ultrasonic vibration of the carbon fiber suspension cross-arm with a diameter distribution of 16-28 mm can be realized by using an ultrasonic vibration tool head Auxiliary glue connection.
本发明提供的上述超声波振动辅助碳纤维悬架横臂胶连接的装置，其工作过程是：首先利用工件夹具——定位滑槽13和第一定位滑块10、第二定位滑块15、有螺纹孔的定位凸台18组合作用将碳纤维管14与铝接头12定位，然后，开启超声波振动装置。超声波发生器7把市电转换成与超声波换能器8相匹配的高频交流电信号，驱动超声波换能器8工作；超声波换能器8将高频交流电信号转变为超声波振动，变幅杆4将机械振动幅值放大后传送到超声波振动工具头9。接着，设置气缸压力，降下超声波振动工具头9，使其压紧至定位夹紧在工件夹具上的碳纤维管14外壁。从而，将超声波振动传递给填充在碳纤维管14与铝接头12间隙中的胶水。The device for the above-mentioned ultrasonic vibration-assisted cross-arm glue connection of the carbon fiber suspension provided by the present invention, its working process is: firstly utilize the workpiece fixture-positioning chute 13 and the first positioning slide block 10, the second positioning slide block 15, threaded The positioning boss 18 of the hole acts in combination to position the carbon fiber tube 14 and the aluminum joint 12, and then the ultrasonic vibration device is turned on. The ultrasonic generator 7 converts the mains power into a high-frequency alternating current signal that matches the ultrasonic transducer 8, and drives the ultrasonic transducer 8 to work; the ultrasonic transducer 8 converts the high-frequency alternating current signal into ultrasonic vibration, and the amplitude The rod 4 amplifies the mechanical vibration amplitude and transmits it to the ultrasonic vibration tool head 9 . Next, the cylinder pressure is set, and the ultrasonic vibration tool head 9 is lowered to be pressed against the outer wall of the carbon fiber tube 14 positioned and clamped on the workpiece fixture. Thus, the ultrasonic vibration is transmitted to the glue filled in the gap between the carbon fiber tube 14 and the aluminum joint 12 .
本发明提供的超声波振动下辅助碳纤维悬架粘接工艺，是利用上述超声波振动装置以及工件夹具实现的，该工艺主要包括以下流程：The auxiliary carbon fiber suspension bonding process under ultrasonic vibration provided by the present invention is realized by using the above-mentioned ultrasonic vibration device and workpiece fixture, and the process mainly includes the following processes:
1.调整工件夹具在超声波试验台5上的安装位置、并用螺栓19将其固定，同时必须确保超声波振动工具头9的初始位置与工件夹具的相对位置满足工件有效粘接部位对中要求，即将超声波工具头9的初始位置调整为铝管接头有效粘接部位的中间位置的正上方。1. Adjust the installation position of the workpiece fixture on the ultrasonic test bench 5 and fix it with bolts 19. At the same time, it must be ensured that the initial position of the ultrasonic vibration tool head 9 and the relative position of the workpiece fixture meet the alignment requirements of the effective bonding part of the workpiece. The initial position of the ultrasonic tool head 9 is adjusted to be directly above the middle position of the effective bonding part of the aluminum pipe joint.
2.使用具有乳化作用的去污剂将加工好的铝接头12和碳纤维管14表面的污渍去除，再用清水冲洗干净。碳纤维管14为3K斜纹亮光管，其外径为20mm，内径为16mm，长度为200mm。2. Use an emulsifying detergent to remove the stains on the surface of the processed aluminum joint 12 and carbon fiber tube 14, and then rinse them with clean water. The carbon fiber tube 14 is a 3K twill bright tube with an outer diameter of 20 mm, an inner diameter of 16 mm, and a length of 200 mm.
所述铝接头12材料为7075航空铝，为保证碳纤维管14与铝接头12之间的配合间隙，即胶层的厚度，铝接头12由数控车床加工而成，其粘接部位的直径为15.9mm，长度为40mm。The material of the aluminum joint 12 is 7075 aviation aluminum. In order to ensure the fit gap between the carbon fiber tube 14 and the aluminum joint 12, that is, the thickness of the adhesive layer, the aluminum joint 12 is processed by a numerically controlled lathe, and the diameter of the bonding part is 15.9 mm, the length is 40mm.
所述去污剂可以采用含有表面活性剂具有乳化作用的清洗剂。The detergent can be a cleaning agent containing a surfactant with an emulsifying effect.
3.使用医用棉签蘸取丙酮将碳纤维管14内表面和铝接头12的粘胶部位清洗干净。3. Use a medical cotton swab dipped in acetone to clean the inner surface of the carbon fiber tube 14 and the glued part of the aluminum joint 12.
在此清洗过程中，医用棉签只能蘸取丙酮一次，当棉签表面出现大片的污渍时，选用新的棉签重新蘸取丙酮擦拭清洗碳纤维管14内表面和铝管接头12的粘接部位，直至蘸取丙酮液体的洁净棉签表面不会出现肉眼可见的比较明显的污渍为止。否则，清洗不合格，需重新清洗。从而保证胶水在碳纤维管14内表面和铝管接头12外表面最佳粘接条件。During this cleaning process, the medical cotton swab can only be dipped in acetone once. When large stains appear on the surface of the cotton swab, use a new cotton swab to dip in acetone again to wipe and clean the bonding parts between the inner surface of the carbon fiber tube 14 and the aluminum tube joint 12 until The surface of the clean cotton swab dipped in acetone liquid does not appear obvious stains visible to the naked eye. Otherwise, the cleaning is unqualified and needs to be cleaned again. Thereby, the best bonding condition of the glue on the inner surface of the carbon fiber pipe 14 and the outer surface of the aluminum pipe joint 12 is guaranteed.
使用丙酮清洗结束后如果碳纤维管14内表面或者铝接头12的粘接部位存在液滴，须烘干。After cleaning with acetone, if there are liquid droplets on the inner surface of the carbon fiber tube 14 or the bonding position of the aluminum joint 12, it must be dried.
4.用配套胶枪配合混合嘴将DP460胶水分别在碳纤维管14内表面和铝接头12的粘接部位涂抹均匀。4. Use the matching glue gun and the mixing nozzle to apply DP460 glue evenly on the inner surface of the carbon fiber tube 14 and the bonding part of the aluminum joint 12 respectively.
上述涂胶过程中，须将碳纤维管14内表面和铝接头12粘接部位的胶水尽量涂抹均匀，同时保证胶层的厚度大于碳纤维管14和铝接头12的配合间隙。During the above gluing process, the glue on the inner surface of the carbon fiber tube 14 and the bonding part of the aluminum joint 12 must be spread as evenly as possible, while ensuring that the thickness of the glue layer is greater than the fit gap between the carbon fiber tube 14 and the aluminum joint 12 .
5.将铝接头12缓慢地完全旋进碳纤维管14中，然后将它们整体一起(避免发生相对移动与转动)放置在工件夹具上定位，并用紧固螺钉16夹紧、固定。5. Slowly and completely screw the aluminum joint 12 into the carbon fiber tube 14, and then place them as a whole (to avoid relative movement and rotation) on the workpiece fixture for positioning, and clamp and fix it with the fastening screw 16.
6.调整气缸2的压力为0.3MPa左右，然后降下超声波振动工具头9，使该工具头压紧至碳纤维管14粘接段外表面。并且，超声波振动工具头9的下降行程应比其初始位置与碳纤维管14的最短距离大0.2—0.5mm左右。6. Adjust the pressure of the cylinder 2 to about 0.3 MPa, then lower the ultrasonic vibration tool head 9 to press the tool head to the outer surface of the bonding section of the carbon fiber tube 14 . Moreover, the descending stroke of the ultrasonic vibration tool head 9 should be about 0.2-0.5 mm larger than the shortest distance between its initial position and the carbon fiber tube 14 .
7.开启超声波发生器7，使其输出频率为20kHz，振幅为5μm左右，对碳纤维管14的外壁进行40s左右的间歇性振动。最后，将碳纤维管14与铝接头12整体从夹紧元件17中取出。7. Turn on the ultrasonic generator 7 so that its output frequency is 20 kHz and its amplitude is about 5 μm, and intermittently vibrate the outer wall of the carbon fiber tube 14 for about 40 s. Finally, the carbon fiber tube 14 is taken out of the clamping element 17 in one piece with the aluminum joint 12 .
超声波振动工具头9对碳纤维管14外壁加载的振动为间歇性振动，振动2s，间歇2s，避免超声波振动时与工具头相接触的碳纤维管14的温度急剧升高。The vibration of the ultrasonic vibration tool head 9 on the outer wall of the carbon fiber tube 14 is intermittent vibration, the vibration is 2s, and the interval is 2s, so as to prevent the temperature of the carbon fiber tube 14 in contact with the tool head from rising sharply during ultrasonic vibration.
在超声波工具头间歇性振动40s的过程中，当振动20s后，松动紧固螺钉16，将碳纤维管14与铝接头12整体在夹具(第一定位滑块10、第二定位滑块15、有螺纹孔的定位凸台18)中旋转180度，然后再定位、夹紧，继续完成剩余的20s的间歇性振动。During the intermittent vibration of the ultrasonic tool head for 40s, after vibrating for 20s, the fastening screw 16 is loosened, and the carbon fiber tube 14 and the aluminum joint 12 are integrated in the fixture (the first positioning slider 10, the second positioning slider 15, with The positioning boss 18) of the threaded hole rotates 180 degrees, then locates and clamps, and continues to complete the intermittent vibration of the remaining 20s.
8.常温下放置至少2小时，直至完全固化。8. Place it at room temperature for at least 2 hours until it is completely cured.
按照上述实施方式，分别利用传统的碳纤维悬架粘接工艺与本发明所述的超声波振动辅助粘胶工艺进行粘接试验。为保证试验的可靠性、说服性、正确性，在每一种粘接工艺进行重复10次操作，进行每组试验有10个试件利用相同的工艺进行粘接。最后，将粘接固化的试件在Zwick材料试验机进行拉伸测试，将得到的数据进行处理得到图7和图8。According to the above-mentioned embodiment, the bonding test is carried out by using the traditional carbon fiber suspension bonding process and the ultrasonic vibration-assisted gluing process of the present invention, respectively. In order to ensure the reliability, persuasiveness and correctness of the test, the operation was repeated 10 times in each bonding process, and 10 specimens were bonded with the same process for each group of tests. Finally, the bonded and cured specimen was subjected to a tensile test on a Zwick material testing machine, and the obtained data were processed to obtain Figures 7 and 8.
由图7可知：与传统的碳纤维悬架的粘接工艺相比较，本发明所提出的基于超声波振动辅助下碳纤维悬架的粘接工艺可以显著增加碳纤维悬架的粘接强度，重复试验的数据结果验证了本发明的粘接工艺可将碳纤维悬架的粘接强度提45％左右。As can be seen from Figure 7: compared with the traditional carbon fiber suspension bonding process, the bonding process based on the ultrasonic vibration-assisted carbon fiber suspension proposed by the present invention can significantly increase the bonding strength of the carbon fiber suspension, and the data of repeated tests The results verify that the bonding process of the present invention can increase the bonding strength of the carbon fiber suspension by about 45%.
由图8可知：与传统的碳纤维悬架的粘接工艺相比较，本发明所提出的基于超声波振动辅助下碳纤维悬架的粘接工艺可以很好地改善碳纤维悬架在胶连接时出现粘接强度波动性大、差异性(不同试件)显著的问题，重复试验的数据结果验证了本发明的粘接工艺可改善碳纤维悬架粘接强度差异性(不同横臂粘接强度的方差)达54％左右，即：本发明工艺可使碳纤维悬架在胶连接时粘接强度稳定性提高50％以上。It can be seen from Fig. 8 that compared with the traditional bonding process of carbon fiber suspension, the bonding process of carbon fiber suspension assisted by ultrasonic vibration proposed by the present invention can well improve the bonding of carbon fiber suspension during glue connection. Intensity fluctuation is large, the difference (different test pieces) is significant, the data result of repeated test has verified that the bonding process of the present invention can improve the carbon fiber suspension bonding strength difference (variance of bonding strength of different transverse arms) up to About 54%, that is: the process of the present invention can increase the stability of the bonding strength of the carbon fiber suspension by more than 50% when glued.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410705188.XACN104479569B (en) | 2014-11-27 | 2014-11-27 | Ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection process and device |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410705188.XACN104479569B (en) | 2014-11-27 | 2014-11-27 | Ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection process and device |
| Publication Number | Publication Date |
|---|---|
| CN104479569A CN104479569A (en) | 2015-04-01 |
| CN104479569Btrue CN104479569B (en) | 2016-08-10 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201410705188.XAActiveCN104479569B (en) | 2014-11-27 | 2014-11-27 | Ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection process and device |
| Country | Link |
|---|---|
| CN (1) | CN104479569B (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105667233A (en)* | 2016-03-25 | 2016-06-15 | 西华大学 | FSC (Formula Student China) formula car carbon fiber suspension and adhesion technology thereof |
| CN106312876B (en)* | 2016-10-19 | 2019-01-18 | 武汉理工大学 | A kind of fixture being glued for ultrasonic activation reinforced carbon fiber plate and metal plate |
| CN106671003B (en)* | 2016-11-18 | 2019-07-23 | 武汉理工大学 | The fixture being glued for ultrasonic activation reinforced carbon fiber plate and metal plate |
| CN106634642A (en)* | 2016-12-14 | 2017-05-10 | 南京航空航天大学 | Ultrasonic-assisted bonding technique |
| CN108633480A (en)* | 2018-07-20 | 2018-10-12 | 中国农业大学 | One elite stand fruit harvests vibrator |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19800038A1 (en)* | 1998-01-02 | 1999-07-08 | Volkswagen Ag | Joining reinforced plastic structural components of vehicle bodywork |
| CN1285460C (en)* | 2004-02-11 | 2006-11-22 | 哈尔滨工业大学 | Ultrasonic vibration assisting resistance implantation welding method for thermoplastic resin base composite material |
| CN104051281B (en)* | 2014-06-13 | 2016-08-31 | 武汉理工大学 | Filling device and method under ultrasonic activation auxiliary flip-chip plastic packaging molding |
| Publication number | Publication date |
|---|---|
| CN104479569A (en) | 2015-04-01 |
| Publication | Publication Date | Title |
|---|---|---|
| CN104479569B (en) | Ultrasonic vibration-assisted carbon fiber suspension cross-arm glue connection process and device | |
| CN202498359U (en) | Boring-gluing-riveting linkage mechanism | |
| CN110355321B (en) | Titanium nail riveting device based on lateral ultrasonic energy field assistance and forming method thereof | |
| CN107012305A (en) | A kind of ultrasonic coldworking strengthened method and device of structural member connecting hole | |
| CN106346192A (en) | Ultrasonic rolling technique | |
| CN112170385B (en) | Laser cleaning device and method for sealing and glue removing of composite material hot-pressing tool | |
| CN109968673B (en) | A kind of integrated friction spot welding method of metal and thermoplastic composite material riveting | |
| CN205228938U (en) | Special fixture of accurate control hot spraying coating bonding strength test piece axiality | |
| CN103710495B (en) | Apparatus and method for combined ultrasonic impact and electric discharge machining | |
| CN109439885A (en) | A kind of ultrasonic impact device | |
| CN204008348U (en) | Multi-usage HF fatigue testing machine | |
| CN108517479B (en) | A kind of materials such as robot manufacture ultrasonic bull percussion mechanism and method | |
| CN103983512A (en) | Hopkinson pulling and pressing integrated experimental device | |
| CN113736969A (en) | Dual-purpose ultrasonic shot peening strengthening device for round rod and flat-plate-shaped test piece | |
| Yan et al. | Mechanism of ultrasonic vibration effects on adhesively bonded ceramic matrix composites joints | |
| CN102653047A (en) | Metal material clinch-bonding joint in-situ adhesive coating and connection method and link mechanism for implementing adhesive coating-clinch | |
| Wang et al. | Study on adhesive-film bonded Al/CFRP joints strengthened by ultrasonic vibration | |
| CN209652385U (en) | A kind of girth joint ultrasonic impact device | |
| CN110055390B (en) | A pressure alternating immersion type inner hole surface strengthening device and method | |
| CN108251876A (en) | A kind of adhesive technology for being used to improve aluminum alloy junction component switching performance | |
| CN203479616U (en) | Fixture for determining bonding strength of low-strength and high-ductility inter-material type-II fracture | |
| CN103454149A (en) | Clamp for determining II type fracture bonding strength between materials with low strength and high ductility | |
| CN206839018U (en) | A kind of rivet pulling device between alloy sheets and carbon fibre composite plate | |
| CN209745733U (en) | A resonant system for multi-axis ultrasonic fatigue test | |
| CN102031543B (en) | Processing method for repairing chromium coating of undercarriage piston rod with unqualified air tightness |
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant |