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摘要:
针对可重复使用运载器冷结构中应用的复合材料蒙皮-金属骨架结构，开展了含初始损伤的金属-复材连接结构的损伤容限试验，并建立对应结构的损伤容限性能预测模型。研究结果表明：含孔边裂纹的金属结构在疲劳载荷作用下会发生裂纹扩展，而且由于连接不对称的影响，上下表面的裂纹扩展速率不一致，致使从外表面进行裂纹观测会造成对损伤尺寸的保守统计；含预置分层的复合材料层合板在挤压载荷作用下出现一定的分层扩展，其主要损伤还是由于复材的挤压疲劳破坏；复材孔边分层会急剧降低金属-复材连接结构的寿命；金属-复材连接结构的损伤容限设计应该重点关注复材孔边分层损伤；建立的金属-复材结构损伤容限性能预测模型预测结果与试验结果吻合良好，能很好的预测结构的损伤扩展过程和扩展寿命，可用于指导该类结构的损伤容限设计。
Abstract:A damage tolerance test of the metal-composite connection structure with initial damage was conducted for the composite skin-metal skeleton structure used in the reusable launch vehicle, and a damage tolerance performance prediction model of the corresponding structure was created. The research results show that metal structures containing initial cracks at the edge of the connection hole will undergo crack expansion under fatigue load. Due to the geometric asymmetry of the connection structure, the crack expansion rates on the upper and lower surfaces are inconsistent, resulting in crack observation from the outer surface causing an error in the damage size. Extrusion load causes some delamination expansion in composite laminates with preset delaminations; extrusion fatigue damage to the composite materials is the primary cause of the damage. Delamination around composite connection holes will drastically reduce the life of the metal-composite connection structure. The damage tolerance design of the metal-composite connection structure should focus on composite hole edge delamination damage. The prediction results of the established metal-composite structure damage tolerance performance prediction model are in good agreement with the test results. It can well predict the damage expansion process and extended life of the structure, and can be used to guide the damage tolerance design of this type of structure.
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Key words:
- reusable launch vehicle /
- structure /
- damage tolerance /
- finite element method /
- damage detection
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图 1 双钉横向连接试验件及主要尺寸
Figure 1. Double-nail transverse connection test piece and main dimensions
图 3 预置分层范围示意图（阴影部分为预置分层区域）
Figure 3. Schematic diagram of preset delamination damage （rangewith shaded areas indicating preset stratification regions）
图 6 含孔边分层试验件疲劳破坏照片
Figure 6. Fatigue failure of test pieces containing delamination at the edge of the hole
图 7 双钉横向连接试验件超声C扫描图像
Figure 7. Ultrasonic C-scan image of double-nail transverse connection test piece
图 11 金属裂纹起始扩展次数N-ΔG拟合结果
Figure 11. Fitting results of crack initial expansion times N and ΔG
图 14 复材疲劳寿命分析有限元模型与界面单元
Figure 14. Finite element model and interface element for composite fatigue life analysis
表 1 TG800-6K-xw/603A复合材料力学性能
Table 1. Mechanical properties of TG800-6K-xw/603A composite materials
E11 /GPa E22 /GPa ν12 XT /MPa XC /MPa YT /MPa YC /MPa S12 /MPa 87 83.7 0.08 1158 720 1046 707 81.4 
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表 2 静强度试验结果
Table 2. Static strength test results
第1件破坏
载荷/kN第2件破坏
载荷/kN第3件破坏
载荷/kN平均值/kN 离散
系数/%15.09 14.92 14.84 14.95 0.70
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表 3 含孔边预置分层试验件加载
Table 3. Loading of test pieces with preset composite partial delamination
组别 载荷水平 峰值载荷/kN 应力比 频率/Hz 试件数量 第1组 45%$ {\sigma }_{\text{b}} $ 6.7 0.1 6 5 第2组 50%$ {\sigma }_{\text{b}} $ 7.5 0.1 6 5 第3组 55%$ {\sigma }_{\text{b}} $ 8.2 0.1 6 5
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表 4 含孔边预置分层复材件剩余寿命试验结果
Table 4. Test results of test pieces with preset delamination in composite materials
组别 N1 N2 N3 N4 N5 N6 试验寿命
平均值对数寿命
离散系数/
%第1组 175333 88750 220792 24718 265513 50125 137539 7.37 第2组 34698 1013 19218 16175 5046 27417 17261 13.10 第3组 2154 4126 2702 15263 12079 4678 6834 8.45
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表 5 含预置裂纹金属疲劳裂纹扩展试验加载方案
Table 5. Loading scheme for fatigue crack growth test of metal with preset cracks
组别 载荷水平 峰值
载荷/kN裂纹截面
应力/MPa应力比 频率/Hz 有效数量 第1组 75%$ {\sigma }_{\text{b}} $ 11.2 79.43 0.1 5 5 第2组 80%$ {\sigma }_{\text{b}} $ 12.0 85.11 0.1 5 5 第3组 83%$ {\sigma }_{\text{b}} $ 12.4 87.94 0.1 5 5
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表 6 含预置裂纹金属件剩余寿命试验结果
Table 6. Test result of remaining life of metal parts with pre-cracks
组别 N1 N2 N3 N4 N5 试验寿命
平均值对数寿命
离散系数/%第1组 37356 77089 78330 39236 76578 61718 3.14 第2组 18821 18209 57063 44236 58264 53188 1.15 第3组 11655 14859 23655 24372 30201 23272 2.58
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表 7 材料断裂表征参数
Table 7. Material fracture performance parameters
$ {c}_{1} $ $ {c}_{2} $ $ {c}_{3} $ $ {c}_{4} $ $ {G}_{\text{C}} $/（$ \text{N}\cdot {\text{mm}}^{{-1}} $） $ \dfrac{{G}_{\text{thresh}}}{{G}_{\text{C}}} $ $ \dfrac{{G}_{\text{pl}}}{{G}_{\text{C}}} $ 2.7×108 −5 1.1×10−7 4.25 9 0.01 0.85
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表 8 仿真结果对比
Table 8. Comparison of simulation results
组别 试验寿命
平均值有限元
计算值仿真与试验的
相对误差/%第1组 61718 69135 12.0 第2组 53188 45334 −14.8 第3组 23272 28066 20.6
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表 9 层内损伤退化准则
Table 9. Intralayer damage degradation criterion
失效模式 材料退化准则 经向拉伸/剪切失效 $ {E}_{11} $,$ {G}_{12} $,$ {G}_{13} $退化到初始值的0.01 经向压缩失效 $ {E}_{11} $,$ {G}_{12} $,$ {G}_{13} $退化到初始值的0.01 纬向拉伸/剪切失效 $ {E}_{22} $,$ {G}_{13} $,$ {G}_{23} $退化到初始值的0.01 纬向压缩失效 $ {E}_{22} $,$ {G}_{13} $,$ {G}_{23} $退化到初始值的0.01
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表 10 层间界面单元属性
Table 10. Interlayer interface element properties
Tn/MPa Ts/MPa Tt/MPa GⅠC/
（N·mm−1）GⅡC/
（N·mm−1）GⅢC/
（N·mm−1）81 81 60 0.2 1.0 1.0
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表 11 仿真结果对比
Table 11. Comparison of simulation results
组别 试验寿命
平均值有限元计算值 仿真与试验的
相对误差/%第1组 137539 131825 −4.15 第2组 17261 17378 0.70 第3组 6834 6309 −7.68
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