JP4194782B2 - Manufacturing method of composite hinge integrated girder - Google Patents

Description

【００３４】
本発明に係る複合材ヒンジ一体桁１１は、想定した設計荷重を充分に満足しており、航空機の機体構造等に充分に適用できることが分かった。
【００３５】
また、本発明者等は、本発明に係る複合材ヒンジ一体桁と、複合材桁材にヒンジ金具を結合した従来の桁とによる重量およびコストの比較実験を行なった。
【００３６】
その実験結果を図１４（ａ），（ｂ）に示す。
【００３７】
図１４（ａ），（ｂ）からも明らかなように、本発明に係る複合材ヒンジ一体桁は、重量については、従来のものに比べて２０％のヒンジ重量軽減、桁全体では部品点数減少に伴ない５％の重量軽減が可能であり、またコストについては、従来のものに比べて４０％程度の加工コストの削減、全コストでも１０％の削減が可能であることが分かった。
【００３８】
なお、前記実施の一形態においては、１個の箱型積層プリフォーム１４とその両側の端部積層プリフォーム１５とでヒンジ部材１３を製作する場合について説明したが、箱型積層プリフォーム１４を複数並設し、それらの両側に端部積層プリフォーム１５を配するようにしてもよい。これにより、３枚以上のラグ部１６を得ることができる。
【００３９】
【発明の効果】
以上述べたように本発明によれば、ドライプリフォームで形成したヒンジ部材とドライプリフォームで形成した桁部材を成型治具にセットし、樹脂を成型治具内に注入し、注入した樹脂をヒンジ部材と桁部材に含浸し、含浸した樹脂を加熱硬化することで複合材ヒンジ一体桁を成形するので、ヒンジ部材が複数枚のラグ部を有するような複雑な形状であっても、作業に複雑な手順を必要とせず、コストダウンを図ることができ、かつ部品点数の低減により軽量化を図ることができる。
【図面の簡単な説明】
【図１】 本発明による複合材ヒンジ一体桁の製造方法により作られた複合材ヒンジ一体桁を示す斜視図。
【図２】 図１の複合材ヒンジ一体桁の適用例を示す分解斜視図。
【図３】 図１の複合材ヒンジ一体桁の分解斜視図。
【図４】 複合材ヒンジ一体桁の成形手段を示す図。
【図５】 箱型積層プリフォームおよび端部積層プリフォームの積層構造を示す分解斜視図。
【図６】 箱型積層プリフォームおよび端部積層プリフォームを上方から見た積層構造を示す図。
【図７】 箱型積層プリフォームおよび端部積層プリフォームを正面側から見た積層構造を示す図。
【図８】 端部積層プリフォームにおける各±４５°中間層プリフォームの突合わせ部の位置を示す図。
【図９】 箱型積層プリフォームおよび端部積層プリフォームのステッチングおよびかがり縫い処理を示す図。
【図１０】 図９のＸ−Ｘ線に沿った断面図。
【図１１】 図９のXI−XI線に沿った断面図。
【図１２】 本発明による複合材ヒンジ一体桁の製造方法を示す図。
【図１３】 （ａ）はアクチュエータ・ヒンジ供試体の強度試験方法を示す図、（ｂ）は一般ヒンジ部供試体の強度試験方法を示す図。
【図１４】 （ａ）は本発明に係る桁と従来の桁材との重量を比較して示すグラフ、（ｂ）は本発明に係る桁材と従来の桁材とのコストを比較して示すグラフ。
【図１５】 航空機の舵面に適用されるヒンジ付き桁材を示す図。
【図１６】 従来のヒンジ付き桁材の構成を示す分離斜視図。
【符号の説明】
１１ 桁材
１２ 桁部材
１２ａ 桁ウエブ
１２ｂ フランジ
１３ ヒンジ部材
１４ 箱型積層プリフォーム
１５ 端末積層プリフォーム
１６ ラグ部
１７ 密閉治具
１７ａ 下型
１７ｂ 上型
１８ 貫通孔
２０ 内層プリフォーム
２１，２２ 中間層プリフォーム
２３ 外層プリフォーム
２５ 内層プリフォーム２
２６，２７ 中間層プリフォーム
２８ 外層プリフォーム
３０ ステッチング
３１ かがり縫い[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a composite hinge-integrated girder applied to an aircraft fuselage structure and the like.
[0002]
[Prior art]
The control surface girder structure of an aircraft requires a hinge as a mounting portion. To use a composite material girder for an aircraft control surface or the like, as shown in FIGS. 15 and 16, a composite material girder is used. 1 is a hinge metal fitting 3 having a lug shape having two lugs 3a and a mounting flange 3b by machining a girder member 2 formed of a composite material into a U-shaped cross section and a metal material such as an aluminum alloy. Are made separately, and the girder member 2 and the hinge fitting 3 are joined by using the fastener 4.
[0003]
Japanese Patent Application No. 7-154756 discloses a fiber reinforced composite material structure integrally formed by an RTM (RESIN TRANSFER MOLDING) molding method. In this fiber reinforced composite material structure, Only stiffeners are provided, and nothing is described about the integral molding of the composite hinge. In order to apply this technology to aircraft control surfaces, etc., it is necessary to manufacture composite girders and hinge brackets separately and assemble the composite girders and hinge brackets using fasteners, as in the prior art. is there.
[0004]
[Problems to be solved by the invention]
In the prior art, in order to manufacture a composite hinged girder structure, it is necessary to manufacture a composite girder member and a hinge bracket separately, and to combine the composite girder member and the hinge bracket using fasteners. In addition, the assembly adjustment of the fastener using shims and the sealing of the mating surface to the contact interface to prevent electrolytic corrosion between the metal and the composite material are required, which increases the cost and weight. There's a problem.
[0005]
Although it is known that it is effective to reduce the cost and weight of the girder structure by forming the hinge bracket into a composite material and integrally forming the composite hinge and the composite girder member, it is as complicated as the hinge part. In order to form a girder structure having a simple structure by prepreg layup, a complicated procedure is required, which is rather a factor of high cost.
[0006]
The present invention has been made in consideration of the above points, and provides a manufacturing method of a composite hinge integral girder that can integrally reduce a composite hinge and a composite girder and reduce cost and weight. The purpose is to do.
[0007]
[Means for Solving the Problems]
A manufacturing method of a composite hinge-integrated girder according to the present invention includes a box-shaped hinge element comprising a dry preform and an end hinge element obtained by dividing the box-shaped hinge element into two to form a hinge member. the formed hinge member and beam member formed by a dry preform was set in the molding jig, to note enter the resin into the molding jig, injected resin is impregnated into the hinge member and the spar member, heat curing the impregnated resin It is composed by doing.
[0008]
In the manufacturing method of the composite hinge integral girder of the present invention, the hinge member can be provided with a through hole, and a bush can be attached to the through hole.
[0009]
In the method for manufacturing a composite hinge-integrated girder according to the present invention, the hinge member can be formed of an end hinge element obtained by dividing a box-type hinge element and a box-type dry preform into two.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
In FIG. 1, reference numeral 11 denotes a composite hinge-integrated girder molded by the method for manufacturing a composite hinge-integrated girder according to the present invention. The composite hinge integrated girder 11 is formed by integrally molding the composite girder member 12 and the composite hinge member 13 by the RTM method. As shown in FIG. 2, the composite hinge integrated girder 11 is used as a girder of a control surface structure of an aircraft, for example.
[0011]
The girder member 12 of the composite hinge integrated girder 11 is formed, for example, by laying up a dry preform made of a plain woven fabric on a forming jig. As shown in FIG. 3, the girder web 12a and the girder web 12a It has a U-shaped cross section having flanges 12b continuous on both sides. As shown in FIG. 3, the hinge member 13 of the composite hinge integrated girder 11 is formed of a box-shaped preform 14 and end preforms 15 and 15 connected to both sides of the box-shaped preform 14 by stitching. And has a hinge shape having two lug portions 16.
[0012]
As shown in FIG. 4B, the composite hinge-integrated girder 11 sets the molded girder member 12 and the hinge member 13 on the lower mold 17a of the sealing jig 17 (for convenience of explanation, one hinge member). 13), the upper die 17b shown in FIG. 4A is coupled to the lower die 17a on which the beam member 12 and the hinge member 13 are set, and the resin is injected into the sealing jig 17, and the injected resin Is formed by impregnating the beam member 12 and the hinge member 13 with heat and curing the impregnated resin.
[0013]
In the composite hinge integrated girder 11, when the hinge member 13 is used as an actuator hinge, as shown on the left side of FIG. Further, in the composite hinge integrated girder 11, when the hinge member 13 is used as a general part hinge, one through hole 18 is processed in the lug part 16 as shown on the right side of FIG. For example, a stainless steel bush 19 is mounted in the through hole 18 of each lug portion 16.
[0014]
The girder member 12 forms a girder web 12a and flanges 12b at both ends thereof by laying up a dry preform made of a plain fabric not impregnated with resin on a forming jig.
[0015]
As shown in FIG. 5 (a), the box-shaped preform 14 of the hinge member 13 has an inner-layer preform 20 that is box-shaped with a woven material having a fiber direction of 0 ° / 90 ° so that the fibers do not become discontinuous. An intermediate layer preform 21 of a woven material having a fiber direction of ± 45 ° and an intermediate layer preform 22 of a woven material having a fiber direction of 0 ° / 90 ° are laminated on the outer side of the inner layer preform 20 in an arbitrary arrangement. And an outer layer preform 23 having a box shape made of a woven material having a fiber direction of 0 ° / 90 °. In this case, the intermediate layer preform 21 having a fiber direction of ± 45 ° is used as the uppermost layer of the intermediate layer.
[0016]
The inner layer preform 20 of the box-shaped preform 14 is formed into a box shape in advance with a fabric material of 0 ° / 90 ° so that the fibers do not become discontinuous, and matches the inner dimensions of the two lug portions 16 to be molded. It is placed on a box-shaped jig made in this way. As shown in FIG. 5B, the ± 45 ° intermediate layer preform 21 and the 0 ° / 90 ° intermediate layer preform 22 are pre-cut into an unfolded shape suitable for a box shape, as shown in FIG. 5B. It is formed by applying a terminal treatment for preventing fiber dropout, and is bent into a box shape at the time of lamination. The outer layer preform 23 is previously formed in a box shape with a 0 ° / 90 ° woven material so that the fibers do not become discontinuous.
[0017]
As shown in FIG. 6, the box-shaped preform 14 of the hinge member 13 has a top surface configuration of 0 ° / 90 ° preform 20, ± 45 ° preform 21, ± 45 ° in order from the inside to the outside. Preform 21, 0 ° / 90 ° preform 22, ± 45 ° preform 21, 0 ° / 90 ° preform 22, ± 45 ° preform 21, ± 45 ° preform 21, 0 ° As shown in FIG. 7, the front structure is a 0 ° / 90 ° preform 20, a ± 45 ° preform 21, ± 45 ° preform 21, 0 ° / 90 ° preform 22, ± 45 ° preform 21, 0 ° / 90 ° preform 22, ± 45 ° preform 21, 0 ° / 90 ° preform Reform 22, ± 45 ° preform 21 ± 45 ° of the preform 21, a 14-layer structure of the ± 45 ° preform 21,0 ° / 90 ° of the preform 23.
[0018]
End laminated preform 15 of the hinge member 13, the upper surface configuration, as shown in FIG. 6, in order from the inside to the outside, 0 ° / 90 ° of the preform 25, the ± 45 ° preform 26, ± 45 ° preform 26, 0 ° / 90 ° preform 27, ± 45 ° preform 26, 0 ° / 90 ° preform 27, ± 45 ° preform 26, ± 45 ° preform 26, It has a nine-layer structure of 0 ° / 90 ° preform 28, and the front structure is 0 ° / 90 ° preform 25 and ± 45 ° preform 26 in order from the inside to the outside as shown in FIG. ± 45 ° preform 26, 0 ° / 90 ° preform 27, ± 45 ° preform 26, 0 ° / 90 ° preform 27, ± 45 ° preform 26, ± 45 ° preform Reform 26, 0 ° / 90 ° preform 8, which is a 9-layer structure of.
[0019]
The inner layer preform 25 is a 0 ° / 90 ° fine article so that the fibers do not become discontinuous in a box-shaped jig made in accordance with the inner dimensions of the two lug portions 16 to be molded. It is formed by cutting the material into half of a box shape. The ± 45 ° intermediate layer preform 26 and the 0 ° / 90 ° intermediate layer preform 27 have a developed shape that matches the shape of the inner layer preform 25 with a dry preform 29 made of a plain plain fabric, as shown in FIG. In addition to pre-cutting, it is formed by applying a terminal treatment for preventing fiber dropout. The 0 ° / 90 ° outer layer preform 28 is formed by dividing a box shape of a 0 ° / 90 ° woven material into two parts so that the fibers do not become discontinuous.
[0020]
As shown in FIG. 8, the ± 45 ° intermediate layer preform 26 is arranged so that the abutting portions 26a are shifted from each other so that the abutting portions 26a are not located at the same position. It is considered not to be the same part. Thereby, the load transmitted to the hinge web portion can be smoothly transmitted.
[0021]
Next, a method for manufacturing the composite hinge integral girder will be described.
First, the box-shaped laminated preform 14 and the end laminated preform 15 are manufactured separately.
[0022]
The box-type laminated preform 14 is arranged on the outside of the inner-layer preform 20 woven in a box shape with the arrangement and the number of laminated layers shown in FIGS. 6 and 7 and ± 45 ° intermediate layer preform 21 and 0 ° / 90 ° intermediate. A layer preform 22 is laminated, and a 0 ° / 90 ° outer layer preform 23 is laminated outside the ± 45 ° intermediate layer preform 21 positioned at the uppermost layer. The box-type laminated preform 14 can prevent the dispersion of the ± 45 ° layer by making the outermost layer a 0 ° / 90 ° layer.
[0023]
The end laminated preform 15 is arranged on the outer side of the inner layer preform 25 obtained by weaving the inner laminated preform 20 of the box-type laminated preform 14 into two parts on the left and right sides in the arrangement and the number of laminated layers shown in FIGS. A 45 ° intermediate layer preform 26 and a 0 ° / 90 ° intermediate layer preform 27 are laminated, and a 0 ° / 90 ° outer layer preform 28 is laminated outside the ± 45 ° intermediate layer preform 26 located at the uppermost layer. To make. The end laminated preform 15 can prevent the ± 45 ° layer from being scattered by setting the outermost layer to a 0 ° / 90 ° layer.
[0024]
As shown in FIGS. 9 to 11, the box-shaped laminated preform 14 and the end laminated preforms 15, 15 are formed by disposing end laminated preforms 15 on both sides of the box-shaped laminated preform 14 and using carbon fibers. Thus, the stitching 30 of the joint surface is performed, and the hinge member 13 is completed by performing the edge stitch 31 of the end portion.
[0025]
Next, a method for manufacturing the composite hinge integrated girder 11 will be described with reference to FIG.
First, the hinge member 13 is set on the lower mold 17a of the sealing jig 17, the fillet R portions 32 and 32 of the hinge member 13 are filled with carbon fiber, and the girder member 12 is laminated thereon.
[0026]
Next, the upper die 17b is set on the lower die 17a to seal the inside of the sealing jig 17, and the vacuuming pipe 33 and the resin impregnation line 34 are connected to the sealing jig 17, and the inside of the sealing jig 17 is evacuated. While impregnating the resin. When the inside of the sealing jig 17 is filled with resin, N ₂ pressure is applied through the stainless tube 35.
[0027]
Next, the resin impregnated in the girder member 12 and the hinge member 13 is heated and cured, and the girder member 12 and the hinge member 13 are molded, whereby the integral molding of the composite hinge integral girder 11 is completed.
[0028]
The integrally formed composite hinge integrated girder 11 is released from the sealing jig 17 and processed 37 into a lug shape of the hinge member 13 to be a finished product.
[0029]
As shown in FIG. 1, the lug portion 16 of the hinge member 13 may be used as an actuator hinge or a general hinge. When used as an actuator hinge, the two through holes 18 are formed. When used as a general part hinge, it is processed into a shape having one through hole 18, and a bush 19 made of, for example, stainless steel is attached to each through hole 18.
[0030]
The bush 19 is attached to each through hole 18 for the following reason.
That is, since the surface pressure strength of the composite material is low, it is not preferable to insert a relatively small-diameter hinge pin directly into the through hole 18 because the load is directly applied to the composite material. This is because, when the bush 19 is attached to the through hole 18, a surface pressure area proportional to the outer diameter of the bush 19 is obtained, so that the load can be reliably transmitted to the lug portion 16.
[0031]
Thus, the integrally formed composite hinge integrated girder 11 is formed by forming the girder member 12 and the hinge member 13 with a dry preform, setting them in the sealing jig 17, and injecting resin so as to be integrally molded. A hinge portion having a complicated shape is integrally formed, and cost reduction and weight reduction can be achieved.
[0032]
【Example】
As shown in FIGS. 13 (a) and 13 (b), the present inventors manufactured an actuator / hinge specimen 13A and a general hinge specimen 13B by the method of the present invention, and each of these specimens 13A, 13B. A load P was applied via load surface loading jigs 38 and 39, and a structural strength test of the hinge portion was performed.
[0033]
Table 1 shows the test results.
[Table 1]

[0034]
It has been found that the composite hinge-integrated girder 11 according to the present invention sufficiently satisfies the assumed design load and can be sufficiently applied to an aircraft body structure and the like.
[0035]
In addition, the present inventors conducted a comparative experiment of weight and cost using the composite hinge integrated girder according to the present invention and a conventional girder in which a hinge fitting is joined to the composite girder.
[0036]
The experimental results are shown in FIGS. 14 (a) and 14 (b).
[0037]
As is clear from FIGS. 14A and 14B, the composite hinge integrated girder according to the present invention has a weight reduction of 20% compared to the conventional one, and the number of parts in the whole girder is reduced. are possible accompanied with no 5% weight reduction in, the costs can also reduce processing costs of about 40% compared with the conventional, it was found to be capable of 10% reduction in overall cost.
[0038]
Note that, in one form of the embodiment has been described for the case of fabricating a hinge member 13 in a single box-type laminated preform 14 and the end laminated preform 15 on both sides thereof, the box-type laminated preform 14 A plurality of side-by-side preforms 15 may be arranged on both sides thereof. Thereby, three or more lug portions 16 can be obtained.
[0039]
【The invention's effect】
As described above, according to the present invention, the hinge member formed of the dry preform and the girder member formed of the dry preform are set in the molding jig, the resin is injected into the molding jig, and the injected resin is the hinge member. Since the composite hinge integrated girder is formed by impregnating the girder member and heat-curing the impregnated resin, even if the hinge member has a complicated shape with multiple lugs, the work is complicated. No procedure is required, cost can be reduced, and weight reduction can be achieved by reducing the number of parts.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a composite hinge-integrated girder made by a method for manufacturing a composite hinge-integrated girder according to the present invention.
2 is an exploded perspective view showing an application example of the composite hinge integrated girder of FIG. 1; FIG.
3 is an exploded perspective view of the composite hinge integral girder of FIG. 1. FIG.
FIG. 4 is a view showing a forming means for a composite hinge-integrated girder.
FIG. 5 is an exploded perspective view showing a laminated structure of a box-type laminated preform and an end laminated preform.
FIG. 6 is a view showing a laminated structure of a box-type laminated preform and an end laminated preform as viewed from above.
FIG. 7 is a view showing a laminated structure of a box-type laminated preform and an end laminated preform as viewed from the front side.
FIG. 8 is a view showing a position of a butt portion of each ± 45 ° intermediate layer preform in the end laminated preform.
FIG. 9 is a diagram showing stitching and overlock processing for a box-type laminated preform and an end laminated preform.
10 is a cross-sectional view taken along line XX in FIG.
FIG. 11 is a cross-sectional view taken along line XI-XI in FIG.
FIG. 12 is a view showing a method of manufacturing a composite hinge integral girder according to the present invention.
FIG. 13A is a diagram showing a strength test method for an actuator / hinge specimen, and FIG. 13B is a diagram showing a strength test method for a general hinge part specimen.
FIG. 14A is a graph showing a comparison of the weights of the girders according to the present invention and conventional girders, and FIG. 14B is a comparison of costs between the girders according to the present invention and conventional girders. Graph showing.
FIG. 15 is a view showing a hinged girder applied to a control surface of an aircraft.
FIG. 16 is an exploded perspective view showing the configuration of a conventional hinged girder.
[Explanation of symbols]
11 Girder material 12 Girder member 12a Girder web 12b Flange 13 Hinge member 14 Box-type laminated preform 15 Terminal laminated preform 16 Lug portion 17 Sealing jig 17a Lower die 17b Upper die 18 Through hole 20 Inner layer preforms 21, 22 Intermediate layer Preform 23 Outer layer preform 25 Inner layer preform 2
26, 27 Intermediate layer preform 28 Outer layer preform 30 Stitching 31 Overlock stitching

Claims (5)

A hinge member is formed by connecting a box hinge element made of dry preform and an end hinge element obtained by dividing the box hinge element into two parts,
Set the beam member formed with the hinge member and dry preform on the molding jig,
A method for producing a composite hinge-integrated girder characterized by injecting resin into a molding jig, impregnating the injected resin into a hinge member and a girder member, and heating and curing the impregnated resin. 2. The method for manufacturing a composite hinge-integrated girder according to claim 1, wherein a through hole is provided in the hinge member, and a bush is attached to the through hole. A box-type hinge element is formed by laminating fabric material dry preforms on the surface constituting the box, and in the outermost layer and innermost layer, a fabric material dry preform having a fiber direction of 0 ° / 90 ° is arranged, and the middle The layer is characterized in that a fabric material dry preform having a fiber direction of ± 45 ° precut into a developed shape of the box and a fabric material dry preform having a fiber direction of 0 ° / 90 ° are folded into a box shape and arranged. The manufacturing method of the composite material hinge integral girder of Claim 1 or 2 . The method of manufacturing a composite hinge-integrated girder according to claim 1 or 2 , wherein the end hinge element is formed by dividing the box hinge element according to claim 3 into two. 5. The method for manufacturing a composite hinge-integrated girder according to claim 3 , wherein the fabric material to be pre-cut is a plain fabric subjected to a terminal treatment for preventing fiber dropout.

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