Producing advanced composite part with complex contour and configuration by automated manufacture process is a challenging research field ever since composite materials have been widely used in aerospace industry. In this study, three potential rubber mandrel designs suitable for producing integral hat-stiffened co-curing panel with large curvature by automatic fiber placement (AFP) technique were discussed. Finite element analysis (FEA) was utilized to study the mechanical behavior of these mandrels during the AFP process. Based on the FEA result, a mandrel design with an outer rubber bladder and a corset inner rubber mandrel enhanced with a flexible steel supporter was selected out. An actual experimental part was manufactured to study the feasibility of such design. Magnetic thickness measurement, ultrasonic defect test, and cross-section examination by metallographic microscope were conducted to study the quality of the experimental part. The results revel that producing hat-stiffened co-curing large curvature panel with desirable quality could be achieved by applying the refined rubber mandrel designed in this research.

中文翻译：

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适用于自动铺纤维技术制造大曲率共固化帽加劲复合材料板的橡胶芯轴设计

自从复合材料广泛应用于航空航天领域以来，通过自动化制造工艺生产具有复杂轮廓和结构的先进复合材料零件一直是一个具有挑战性的研究领域。在这项研究中，讨论了三种适用于通过自动纤维铺放（AFP）技术生产大曲率整体帽加筋共固化面板的潜在橡胶芯轴设计。利用有限元分析 (FEA) 研究 AFP 过程中这些心轴的机械行为。根据有限元分析结果，选择了一种带有外部橡胶气囊和紧身胸衣内部橡胶心轴的心轴设计，并用柔性钢支撑件增强。制造了一个实际的实验部件来研究这种设计的可行性。通过磁测厚、超声波缺陷检测、金相显微镜断面检查等手段研究实验件的质量。结果表明，应用本研究设计的精制橡胶芯轴可以生产出质量理想的帽筋共固化大曲率板材。