目的 针对连续碳纤维复合材料在熔融沉积成型中多材料挤出不同步、温度场不均及界面结合质量不稳定导致的打印构件力学性能离散、结构精度不足等问题,提出一种高性能多材料集成挤出头及其控制系统,以实现对复合材料打印过程的精确协同控制。方法 首先,基于对短纤维丝材流动特性与连续纤维在线浸渍机理的分析,完成了多通道挤出头结构的设计。该挤出头采用分区独立温控模块,分别为不同材料挤出打印提供精确的热管理;集成微型剪丝机构,以实现打印空移过程中的纤维精准切断与重启。其次,构建了通过PID算法实时调节加热器功率的集成化打印控制系统,并同步协调三轴运动平台、丝材送进电机与纤维送进伺服机构。最后,采用万能试验机对比分析了未增强基体与连续碳纤维增强复合材料试样的力学性能。结果 与未增强基体相比,采用连续碳纤维增强的复合材料力学性能得到显著提升,其拉伸强度达到653.7 MPa,拉伸弹性模量提升至32 675.95 MPa。结论 所提出的多挤出头设计与控制系统有效提升了连续碳纤维复合材料的打印质量和力学性能,实现了多材料打印的稳定协调与控制,为复杂纤维增强结构的增材制造提供了可靠的工艺解决方案。
Abstract
The work aims to propose a high-performance multi-material integrated extrusion head and its control system to address the problems of mechanical performance dispersion and insufficient structural accuracy of printed components caused by asynchronous extrusion of multiple materials, uneven temperature field, and unstable interface bonding quality in the melt deposition molding of continuous carbon fiber composites, so as to achieve precise collaborative control of the printing process of composites. Firstly, based on the analysis of the flow characteristics of short fiber filaments and the online impregnation mechanism of continuous fibers, the design of a multi-channel extrusion head structure was completed. The extrusion head featured partitioned, independent temperature control modules to provide precise thermal management for extrusion printing of various materials. It also incorporated an integrated micro wire cutting mechanism, enabling precise fiber cutting and restart during the printing process. Secondly, an integrated printing control system was constructed to adjust the power of the heater in real time through a PID algorithm, and synchronously coordinate the three-axis motion platform, wire feeding motor, and fiber feeding servo mechanism. Finally, the mechanical properties of unreinforced matrix and continuous carbon fiber reinforced composite specimens were compared and analyzed with a universal testing machine. Experimental data showed that, compared with the unreinforced matrix, the mechanical properties of composites reinforced with continuous carbon fibers were significantly improved, with a tensile strength of 653.7 MPa and a tensile modulus of elasticity increased to 32 675.95 MPa. In conclusion, the proposed multi extrusion head design and control system effectively improves the printing quality and mechanical properties of continuous carbon fiber composites, achieves stable coordination and control of multi-material printing, and provides a reliable process solution for additive manufacturing of complex fiber-reinforced structures.
关键词
增材制造 /
多挤出头 /
打印控制系统 /
纤维增强复合材料 /
设计与优化
Key words
additive manufacturing /
multi extrusion head /
printing control system /
fiber reinforced composites /
design and optimization
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基金
江苏省基础研究计划自然科学基金-青年基金项目（BK20230173）; 江苏省高等学校基础科学（自然科学）研究面上项目（23KJB460031）; 江苏省食品先进制造装备技术重点实验室开放课题资助项目（FM-202304）; 江苏省产学研项目（BY20240828）
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