Specific production process of carbon fiber parts

        When ultra-light and ultra-strong carbon fiber enters the public's life, when this new material is frequently combined with a variety of high-tech equipment, many people outside the industry are still not very clear about what steps and processes need to go through from carbon fiber composite materials to carbon fiber parts. Today, I will give you a brief introduction.

         Stage 1: Drawing design   

The application side is the leader of this stage, and the concept of carbon fiber parts in this period is still a "substitute", that is to say, before it really comes out, it is usually metal parts. Carbon fiber parts should not only completely replace the original metal parts in structure and function, but also far exceed the value of the original parts.  

         For example, the mechanical roller has been made of metal before, but now the roller body is reduced by 35% -45% by using carbon fiber material. The power consumption of the whole equipment is significantly reduced, but the production efficiency is greatly improved. The most important thing is that the deformation of the roller body is small and the fatigue resistance is better, so the quality of the products produced by the equipment is also guaranteed.   

        At this stage, the mechanical designer of the application side should fully understand the material characteristics of carbon fiber composites and the basic manufacturing process of carbon fiber parts, and make a new design of carbon fiber parts on the basis of the original application of metal parts.   

         Stage 2: Proofing and experiment          When the carbon fiber parts manufacturer gets the design draft, it will conduct in-depth communication and discussion with the application side on the production method and final performance requirements of the parts, and simplify the production process as much as possible on the premise of meeting the performance requirements put forward by the application side. Adopt a more realistic and less costly production plan. In the proofing stage, the manufacturer of carbon fiber parts will make a very small number of samples according to the scheme agreed by both parties, and deliver them to the application party for relevant performance testing. In this regard, in addition to conventional pipes, plates and other basic components, carbon fiber parts manufacturers will not and can not provide a specific product performance test report. Because customized products have their specific application environment and performance requirements, the application side undertakes the task of sample testing, some need to rely on third-party testing and identification, and some need to apply samples to mechanical equipment, through field operation experiments to test.

        Stage 3: Optimization and adjustment    

        If the design of carbon fiber parts is relatively complex or the application requirements are high, the application party and the production party can also optimize the design of the sample and adjust the production process according to the specific experimental results. For the application side, how to break the original design mode of metal parts and give carbon fiber parts a new design concept is very important; for the production side, how to control the details such as layer design, molding scheme selection, temperature and pressure, step by step close to the requirements of the application side, this is the key to success. Each product is very different, how to make full use of the performance advantages of carbon fiber composites and meet the specific needs of customers is the core technical problem of carbon fiber parts enterprises.

        Stage 4: Mass production   

        When the sample finally passes the test of the application party, it will enter the mass production stage. The problems in this stage mainly include two aspects: one is how to reduce the production cost to the greatest extent; the other is how to ensure the product quality and shorten the delivery cycle in mass production.   

        To solve the above problems, we need to give consideration to both hardware and software. Take the batch order of the mechanical arm of new materials as an example: firstly, in terms of hardware, the time of forming equipment occupied by each mechanical arm is fixed, so the number of supporting forming, processing and testing equipment should be sufficient; Secondly, the professional level and work efficiency of the production personnel directly affect the consumption of raw materials and the final qualified rate of finished products. That is to say, the mass production of carbon fiber parts ultimately tests the comprehensive strength of parts manufacturers.