Carbon fibres used as a honeycomb core material (subject to a proper in-depth analysis of their reinforcement patterns) allows solving the thermo-dimensional stability problem of the units for space systems. Based on the results of numerical simulations with the support of finite element analysis, the paper provides an evaluation of the accuracy of analytical dependencies for the determination of the moduli of elasticity of a carbon fibre honeycomb core in tension/compression and shear. It is shown that a carbon fibre honeycomb reinforcement pattern has a significant impact on the mechanical performance of the carbon fibre honeycomb core. For example, for honeycombs measuring 10 mm in height, the maximum shear modulus values corresponding to the reinforcement pattern of ±45° exceed the minimum values for a reinforcement pattern of 0° and 90° by more than 5 times in the XOZ plane and 4 times for the shear modulus in the YOZ plane. The maximum modulus of the elasticity of the honeycomb core in the transverse tension, corresponding to a reinforcement pattern of ±75°, exceeds the minimum modulus for the reinforcement pattern of ±15° more than 3 times. We observe a decrease in the values of the mechanical performance of the carbon fibre honeycomb core depending on its height. With a honeycomb reinforcement pattern of ±45°, the decrease in the shear modulus is 10% in the XOZ plane and 15% in the YOZ plane. The reduction in the modulus of elasticity in the transverse tension for the reinforcement pattern does not exceed 5%. It is shown that in order to ensure high-level moduli of elasticity with respect to tension/compression and shear at the same time, it is necessary to focus on a reinforcement pattern of ±64°. The paper covers the development of the experimental prototype technology that produces carbon fibre honeycomb cores and structures for aerospace applications. It is shown by experiments that the use of a larger number of thin layers of unidirectional carbon fibres provides more than a 2-time reduction in honeycomb density while maintaining high values of strength and stiffness. Our findings can permit a significant expansion of the area of application relative to this class of honeycomb cores in aerospace engineering.

• Klíčová slova
• experimental prototype technology, finite element analysis, modulus of elasticity, thermo-dimensional stability,
• Publikační typ
• časopisecké články MeSH

Currently, prefabricated panel structures are typical products made of polymeric composite materials. The integrity of the composite panels, their structure and accuracy of making a contour are largely associated with the manifestation of residual technological stresses. The above phenomena and associated stress-strain behaviour inevitably occur in the process of moulding of the composite products. However, their value, nature, time of occurrence and dynamics of growth can be fully controlled and regulated. The paper deals with the study of the effect of moulding pressure on the quality of a composite product. A dependence is presented that allows us to determine the time for the degassing of the polymeric composite material package at the given temperature and pressure to obtain a monolithic and nonporous structure. It is shown that the peak of the maximum volatile-matter yield for the considered binder types lies in the temperature range where the degree of curing does not exceed 10%; that is, the viscosity values do not prevent the removal of volatile fractions. The effect of moulding pressure on the values of the volume content of the reinforcing material has been studied, and the dependence of the required thickness of the absorbent layer on the parameters of the package of polymer composite material and pressure has been obtained. The dependence of the required thickness of absorbent layer on the parameters of the package of polymeric composite material and pressure has been obtained. The mathematical model developed by us provides an opportunity to predict the stress-strain behaviour of a composite structure at any time during the moulding process. The model is closely related to chemo-viscous and thermal models. It allowed us to synthetize a method for choosing the rational parameters of the moulding process (temperature, pressure, and time), materials of additional layers and equipment. The experiments proved the presence of several defects, such as de-lamination of edges, waviness, swelling and poor adhesion of upper layers in the specimen of the composite panel cooled stepwise in the absence of the vacuum pressure. The surface quality of the specimen of the panel cooled stepwise under vacuum pressure was significantly better, and no visible defects were observed. The obtained theoretical values of deflections, considering the change in physic-mechanical characteristics that depend on the temperature and rheonomic properties of the material, showed an error that did not exceed 7%, compared to the experimental data. Our results can be applied at the enterprises engaged in designing and manufacturing panel structures of polymeric composite materials.

• Klíčová slova
• equipment, process parameters, temperature differential, thermoelasticity,
• Publikační typ
• časopisecké články MeSH

Currently, we observe extensive use of products made of polymeric composite materials in various industries. These materials are being increasingly used to manufacture large-sized structural parts that bear significant loads. However, increase in the volume of composites used in critical structures is impeded by the instability of properties of the resulting products. In most cases, the reason for this is the residual thermal stress-strain behaviour of the composite structure. This paper deals with the development of a method to predict the residual stress-strain behaviour depending on the heating conditions and distribution of the temperature field over the thickness of the moulded composite package. The method establishes the relationship between moulding process parameters and the effect of the auxiliary and basic equipment on the distribution of the temperature field, stresses, and strains in the moulded product. It is shown that the rate of temperature change at the stage of heating has its effect on the amount of residual deformation of the structure. Experimental studies have been carried out to determine the influence of several factors (rates of heating and cooling) on the residual deflection of the composite panel. Experimental data proves that specimens moulded under conditions of an increased heating rate get a greater deflection than those moulded at a lower heating rate. The error of results during the full-scale experiment did not exceed 6.8%. Our results provide an opportunity to determine the residual thermal stress-strain behaviour of the moulded structure with the required degree of accuracy without a series of experiments. It allows us to significantly simplify the practical implementation of the developed method and avoid any additional production costs.

• Klíčová slova
• equipment, process parameters, temperature differential, thermoelasticity,
• Publikační typ
• časopisecké články MeSH

Translucent elements in the form of truncated cones, which are made of organic glass, are widely used in the structures of portholes, submersible vessels, space vehicles, pressure chambers, teleboxes and other types of technical equipment. The decisive factor in designing portholes is to ensure the strength of their translucent elements. In order to reduce the weight of portholes and, accordingly, to increase the payload, it is necessary to optimise the geometric parameters of the translucent elements, which include the tapering angle and the ratio of thickness to radius of the smaller base. The paper deals with development of the applied (engineering) method for determining the stress-strain behaviour of the conical translucent elements of portholes made of organic glass under the action of a uniform hydrostatic pressure. Finite-element modelling of the translucent element of the conical porthole is performed, with the calculation of its stress-strain behaviour. External hydrostatic pressure of 10 MPa, absence of loads from the inside and continuous sliding of the translucent element with friction along the conical supporting surface of the porthole metal body are the boundary conditions for the computational model. Full-scale tests of translucent elements of portholes made of organic glass were performed under the action of uniform hydrostatic pressure. Analysis of the influence of geometric characteristics of the portholes on stress-strain behaviour showed that the increase in the tapering angle at the constant relative thickness of the translucent element reduced its axial displacement in all cases. Equivalent stresses acquire minimum values when the tapering angle is in the range from 75° to 105° (when the relative thickness increases, the optimal tapering angle becomes smaller). It is shown that the developed method for determination of the stress-strain behaviour of the conical translucent elements of portholes made of organic glass reflects the real picture of deformation and agrees with the results of full-scale tests. Results of the work allow us to choose the rational parameters of the translucent element for increasing the reliability of portholes through the creation of an effective distribution of stresses and strains in the translucent element, and improving its optical characteristics due to a relatively small deflection in operation.

• Klíčová slova
• hydrostatic load, organic glass, polymethyl methacrylate plastic, translucent element,
• Publikační typ
• časopisecké články MeSH

Repair procedures with the use of composite patches are considered to be the most effective among the current technologies of repair of the structures of various applications. In the process of moulding-on of a patch made of polymeric composite material by means of curing, technological stresses arise in the patch. Determination of residual technological stresses is a priority task for the modelling of the repair process. Reduction of residual stresses can be achieved by optimization of the mode of repair patch curing. For meeting this objective, the method for determination of technological stresses, which arise in the structure under repair in the process of curing of a composite patch, has been developed. The method takes into account the shrinkage, change in physico-mechanical characteristics, rheological processes occurring in the binder during moulding process, and determination of stresses in the structure under repair at any time. Therefore, premature failure of the repair joint at the stage of repair can be avoided. It is shown that the method adequately describes the level of deformations and stresses in the structure being repaired at the stage of heating and holding of the composite patch. Increase in the moulding temperature leads to a reduction in residual stresses in the structure under repair. However, current stresses at the stages of heating and temperature holding are increased significantly. Reliability of assumptions and developed method is confirmed by the comparison with the experimental data. The obtained experimental graph of total deformation of the composite patch allowed us to clearly determine the moment of residual stress occurrence in the structure under repair. This moment matches quite exactly (with the discrepancy not exceeding 5 min) the gel point determined analytically based on dependence of the degree of curing on the moulding mode. Consequently, the research together with the results previously obtained allows making an integrated choice of geometric parameters of the repair composite patch and temperature-time regime of its curing in order to ensure the specified level of strength and stiffness of the structure under repair.

• Klíčová slova
• binder shrinkage, gelation, temperature–time regime,
• Publikační typ
• časopisecké články MeSH