Abstract:

Objective At present, the manufacturing of carbon fiber preforms predominantly relies on manual operations, which is not only highly inefficient and labor-intensive but also causes significant variability and inconsistency into the production process. Manual handling adversely affects the uniformity and quality of punctures, leading to defects such as fiber misalignment, incomplete penetration, and uneven tension distribution. These issues ultimately compromise the mechanical performance and structural integrity of the final composite components. To address these challenges, the research reported in this paper aims to design and develop an automated system dedicated to the fabrication of carbon fiber preforms. The primary goals are to minimize human intervention, standardize the puncture process, enhance production efficiency, and most importantly, improve the reliability and repeatability of preform quality. By integrating advanced mechanization and control technologies, the proposed system seeks to establish a robust and scalable manufacturing solution suitable for industrial applications.

Method A comprehensive design of the mechanical structure was presented for an integrated puncture virtual prototype. The design process involved detailed modeling and simulation of the puncture mechanism to optimize its performance and durability. Specifically, a friction simulation analysis was conducted to examine the interaction between a steel needle array and a single layer of carbon fabric during the penetration process. This enabled a deeper understanding of the forces and deformations involved. Furthermore, a rigorous force analysis was performed on the puncture needle to evaluate its structural behavior under operational loads. The scientific validity and feasibility of the virtual prototype were verified through a multi-step approach, combining computational modeling with empirical validations. Advanced engineering software, including ANSYS and Solidworks, was employed to simulate and analyze critical aspects such as stress distribution, buckling resistance, and friction characteristics. These steps ensured that the design was both scientifically sound and practically viable.

Results This research addressed several key issues associated with the 3D stereoscopic puncture technology for composite materials. In the mechanical design, a high-precision ball screw lifter was incorporated to significantly enhance the stability and positioning accuracy of the needle during piercing operations. The carbon cloth grasping mechanism was designed with a three-axis modular system, providing greater flexibility and adaptability in handling the material. Through mathematical abstraction and structural analysis, the critical maximum buckling value of the puncture needle was calculated, offering important insights into its performance limits. Three distinct failure modes, i.e., fiber bending around the needle, fiber breakage, and fiber accumulation, of the carbon cloth following puncture were identified and analyzed. Frictional simulation experiments conducted using ANSYS software revealed that the friction force between the steel needle and carbon cloth exhibits a nonlinear increase with penetration depth. Static structural analysis of the primary stressed component-the steel needle-was carried out via ANSYS Workbench. The results confirmed that deformation was minimal and within acceptable limits, ensuring that the needle's functionality remains uncompromised throughout the puncture process.

Conclusion This study successfully accomplished the design and development of an integrated puncture machine for automated carbon fiber preform manufacturing. A mechanical model describing the behavior of the puncture needle was established, and a detailed virtual prototype was constructed using Solidworks. The frictional interactions between the needle and carbon cloth were thoroughly investigated through simulation, providing valuable data for optimizing the process parameters. Computational and simulation results collectively demonstrated the rationality, efficiency, and reliability of the structural design. The proposed system not only reduces dependency on manual labor but also enhances production consistency, operational efficiency, and product quality. These findings underscore the practical applicability of the automated equipment in industrial settings and contribute to the advancement of intelligent manufacturing technologies for composite materials.

Key words: integrated puncture virtual prototype, mechanical structure design, composite material, 3-D fabric, 3-D preform, puncture needle stress analysis, static structural evaluation