The invention provides a large-curvature special-shaped surface large-height
honeycomb co-curing sandwich structure
composite material and a forming method thereof. The forming method comprises the following steps: shaping and curing a pre-impregnated and semi-cured
aramid paper
honeycomb on a male die to obtain a
honeycomb core blank; placing the honeycomb core blank on a female die, filling
polystyrene foam in the range of three to five honeycomb grids inwards according to the net size outline of a honeycomb core, pre-curing the
polystyrene foam to obtain a rigidity pre-reinforced honeycomb core blank, and
processing the honeycomb core blank to a theoretical size; and preparing a laminated layer of an outer
skin, a reinforcing block and an inner
skin prepreg from hot-melt prepreg, assembling the laminated layer with a honeycomb core and an embedded part, and curing to obtain the honeycomb co-curing sandwich structure
composite material. The honeycomb core rigidity pre-reinforcement,
laser projection assisted honeycomb forming and appearance
processing technology and the sandwich structure
assembly co-curing technology are adopted, collapse deformation of the honeycomb core in the curing forming process is avoided, and the formed
composite material has the good
internal quality, the good appearance size precision and the good embedded part position precision.