Hollow blade manufacturing process comprising gluing procedure

Abstract

The invention relates to a hollow blade manufacturing process comprising a cementing procedure, which comprises the following steps of: paving a high-temperature cured structural adhesive film in a part cementing area, performing bubble removal preheating treatment, sucking two ends of a blade panel by using a vacuum chuck, vertically placing the blade panel in a corresponding area of a blade body, uniformly sinking the blade panel into the blade body, and performing hot pressing on the blade panel. Cutting a high-temperature curing adhesive film into thin strips of about 3mm, covering a gap between the blade panel and the part, firstly placing a non-porous isolating film to cover the blade panel, then placing a pressure equalizing plate tool, enabling the edge of the pressure equalizing plate tool to be flush with the blade panel, manufacturing a high-temperature vacuum bag on the surface of the blade body, and starting a program to heat, pressurize and cure the part. In a word, the processing efficiency is high, the gluing quality is improved, the problems of gluing debonding and uneven glue layer thickness of the hollow blade thin-wall panel are solved, and the method has the advantages that manpower and material resources are saved, and the method is suitable for large-scale production.

Description

Technical Field

[0001] The invention belongs to the technical field of aviation turbofan engines, and in particular relates to a hollow blade manufacturing process including a gluing process. Background Art

[0002] A turbofan engine is a gas turbine aircraft engine. Its main feature is that the area of ​​its first-stage fan blades is much larger than that of a turbojet engine. The part of the turbojet engine through which part of the air passes is called the inner duct, and the outer part through which the air passes through the first-stage booster blades driven by the internal turbine is called the outer duct. The booster blades have the functions of both propellers and compressed air, and can provide direct thrust for part of the inhaled air through the periphery of the jet engine. The inner and outer ducts jointly generate thrust, and can have the dual thrust supply of turbopropellers and turbojet propulsion engines at the same time.

[0003] Turbofan engines are widely used in the aviation field, and have also been developed on a large scale in the civilian field in recent years. However, as the bypass ratio of civil turbofan engines continues to increase, the outer duct diameter continues to increase, and the size of the fan outlet guide vane increases accordingly, resulting in a large number of blades, generally dozens of blades, and the blade body of the fan outlet guide is heavy, which will also cause the outer duct weight to increase sharply, making it inconvenient to use the fan outlet guide vane. If the weight of the fan outlet guide vane can be reduced, it will be of significant significance to the weight reduction of the entire engine.

[0004] Among them, the hollow aluminum alloy blade is an advanced structural component used in aircraft engines. It reduces weight by means of an internal hollow design while maintaining or improving structural strength and rigidity. This design can effectively reduce the overall weight of the engine, thereby improving fuel efficiency and overall performance. However, it is not widely used in turbofan engines. At the same time, the hollow aluminum alloy blade is generally sealed by a bonding process during the processing process, which can effectively ensure the uniformity of the bonding part and the overall structural stability. However, the existing bonding process still has many problems during use. First, there is a bubble problem during the laying process of the adhesive film of the hollow blade bonding high-temperature curing structure, which is very easy to cause local debonding or weak bonding in the bonding area. Secondly, during the curing and molding process of the existing hollow aluminum alloy blade in the autoclave, there will also be a problem of glue layer porosity caused by warping around the edge of the thin-walled aluminum alloy panel. There are also problems of local debonding in areas with larger curvatures and uneven thickness between the edge and the interior of the panel during the later finishing process. Therefore, there is an urgent need for a hollow blade manufacturing process including a bonding process to solve the above-mentioned problems. Summary of the invention

[0005] In view of this, the present invention provides a manufacturing process for hollow blades including an adhesive bonding process, which is applied to an aero-turbofan engine to solve the technical problems of high cost, low efficiency, easy generation of air bubbles during the adhesive bonding process, local debonding or weak bonding in the adhesive bonding area, the existence of adhesive layer pores around the edges of the thin-walled aluminum alloy panel, local debonding in areas with a large curvature, and uneven internal thickness after finishing the panel edges in the later stage.

[0006] To achieve the above technical objectives, the specific technical solutions adopted by the present invention are as follows:

[0007] A manufacturing process for hollow blades including an adhesive bonding process, comprising the following steps:

[0008] S1. Adhesive film construction

[0009] Lay a high-temperature curing structural adhesive film on the adhesive bonding area of the part and perform preheating treatment for exhausting air bubbles.

[0010] S2. Place the blade panel

[0011] Use a vacuum chuck to suck both ends of the blade panel and vertically place it in the corresponding area of the blade body, so that the blade panel evenly sinks into the blade body.

[0012] S3. Place the adhesive film

[0013] Cut the high-temperature curing adhesive film into strips about 3 mm wide and cover the gap between the blade panel and the part.

[0014] S4. Place the equalizing plate tooling

[0015] First place a non-porous isolation film to cover the blade panel, and then place the equalizing plate tooling. The edge of the equalizing plate tooling is flush with the blade panel.

[0016] S5. Make a high-temperature vacuum bag

[0017] Make a high-temperature vacuum bag on the surface of the blade body, evacuate the air and detect the airtightness of the vacuum bag. Place load point thermocouples at both ends of the blade.

[0018] S6. Autoclave curing

[0019] Place the part with the vacuum bag made in the autoclave, start the program to heat and press the part for curing.

[0020] S7. Demolding

[0021] Take out the cured part from the autoclave, remove the vacuum bag, and take out the equalizing plate tooling.

[0022] In step S1, lay the high-temperature curing adhesive film on the bonding area of the part, make a high-temperature vacuum bag to evacuate and compress the adhesive film, remove the internal air bubbles between the adhesive film and the blade body, press the R area and the side vertical edge area with a smooth scraper to prevent the high-temperature curing structural adhesive film from bridging to form a void area. After pre-evacuating for 10 minutes, use a hot air gun to preheat the adhesive film at 40-50°C to increase the adhesion between the adhesive film and the part surface, and prevent the adhesive film from moving or locally generating wrinkles and air bubbles during the process of removing the vacuum bag for subsequent operations.

[0023] Further, in step S1, the part is cleaned before bonding. Clean the bonding surface of the part to be bonded and the bonding surface of the tooling with acetone, and let it dry naturally.

[0024] Further, in step S1, after the part is cleaned, surface treatment is carried out. Perform phosphoric acid anodizing treatment on the part body and brush the corrosion inhibitor primer.

[0025] Further, in step S1, the adhesive film is cut according to the shape of the workpiece, and the adhesive film is 3-5 mm larger than the bonding area of the part.

[0026] Further, in step S2, before placing the blade panel, cut off the excess adhesive film along the edge of the bonding area of the blade body, and leave the adhesive film on the side vertical surface with a height of 1-2 mm.

[0027] Further, in step S2, the positions of the blade panel and the blade body correspond, and the bonding area of the part is within the coverage of the blade panel.

[0028] Further, in step S4, the size and contour of the equalizing plate tooling are the same as those of the bonding area of the part, and the equalizing plate tooling is made of high-temperature resistant rubber material.

[0029] Further, in step S4, the equalizing plate tooling is located above the blade body, the blade body is arranged between the equalizing plate tooling and the part, and two lifting ring through holes are arranged above the equalizing plate tooling to facilitate the removal of the equalizing plate tooling.

[0030] Further, in step S5, two vacuum nozzles are arranged on the high-temperature vacuum bag, there are two thermocouples, and they are respectively located at both ends of the high-temperature vacuum bag. The two vacuum nozzles are also respectively located at both ends of the high-temperature vacuum bag, and there is a distance from the corresponding thermocouples respectively.

[0031] Adopting the above technical solutions, the present invention can also bring the following beneficial effects:

[0032] 1. The present invention relates to a manufacturing process for hollow blades including a bonding process. By using vacuum pumping and auxiliary heating means to lay a high-temperature curing adhesive film, the internal quality problems caused by the non-adhesion of the adhesive film to the surface of the hollow blade parts are solved. By controlling the stress area of the blade panel with a uniform pressure plate tooling, the quality problem of the adhesive debonding at the panel edge caused by the deformation of the panel sinking into the hollow unsupported area during heating and pressurization curing due to the hollow structure of the blade is solved, ensuring the bonding quality between the entire blade panel and the blade body, and promoting the development of technology in the field of hollow blade manufacturing.

[0033] 2. The present invention relates to a manufacturing process for hollow blades including a bonding process. The bonding of the hollow blade body and the panel is completed by means of autoclave curing, which is suitable for mass production curing, has high work efficiency, improves the bonding quality, solves the problems of adhesive debonding of the thin-walled panel of the hollow blade and uneven adhesive layer thickness, saves manpower and material resources, and has very good economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0035] Figure 1 It is a program flow block diagram of a manufacturing process for hollow blades including a bonding process according to the present invention; figure;

[0036] Figure 2 It is a schematic diagram of the positional relationship between parts and the bonding area in a specific embodiment according to the present invention;

[0037] Figure 3 It is a schematic diagram of the structure of a uniform pressure plate tooling in a specific embodiment according to the present invention;

[0038] Figure 4 It is a schematic diagram of the cooperation relationship between parts and a uniform pressure plate tooling in a specific embodiment according to the present invention;

[0039] Figure 5 It is a schematic diagram of the structure of a high-temperature vacuum bag in a specific embodiment according to the present invention;

[0040] 1. Part; 2. Bonding area; 3. Uniform pressure plate tooling; 4. Hoop through hole; 5. High-temperature vacuum bag; 6. Vacuum nozzle; 7. Thermocouple. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0041] The embodiments of the present invention will be described in detail below with reference to the drawings.

[0042] The following describes the embodiments of the present invention through specific examples. Those skilled in the art can easily understand the other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments. The present invention can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0043] It should be noted that the following describes various aspects of the embodiments within the scope of the appended claims. It should be obvious that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is illustrative only. Based on the present invention, those skilled in the art should understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects described herein can be used to implement the device and / or practice the method. In addition, this device and / or method can be implemented using other structures and / or functions in addition to one or more of the aspects described herein.

[0044] It should also be noted that the drawings provided in the following embodiments only illustrate the basic concept of the present invention schematically. The drawings only show the components related to the present invention, rather than being drawn according to the number, shape, and size of the components in actual implementation. The type, quantity, and ratio of each component in its actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0045] In addition, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0046] In one embodiment of the present invention, as Figures 1 to 5 shown, a manufacturing process for a hollow blade including a bonding process includes the following steps:

[0047] (1) Cleaning of Part 1

[0048] Clean the bonding surface of Part 1 to be bonded and the bonding surface of the tooling with acetone and air dry naturally.

[0049] (2) Surface Treatment

[0050] Phosphoric acid anodizing treatment is carried out on the body of Part 1, and a corrosion inhibitor primer is brushed.

[0051] (III) Cutting the adhesive film

[0052] Cut the adhesive film according to the shape of the workpiece. The adhesive film is 3 - 5 mm larger than the bonding area 2 of Part 1.

[0053] (IV) Adhesive film construction

[0054] Lay the high-temperature curing adhesive film on the bonding area 2 of Part 1, make a high-temperature vacuum bag 5 to vacuum compress the adhesive film, remove the internal air bubbles between the adhesive film and the blade body, press the R area and the side vertical edge area with a smooth scraper to prevent the formation of void areas due to the bridging of the high-temperature curing structural adhesive film. After pre-evacuating for 10 minutes, preheat the adhesive film with a hot air gun at 40 - 50 °C to increase the adhesion between the adhesive film and the surface of Part 1, and prevent the adhesive film from moving or local wrinkles and air bubbles from occurring during the process of removing the vacuum bag for subsequent operations;

[0055] (V) Adhesive film cutting

[0056] Cut off the excess adhesive film along the edge of the bonding area of the blade body, and keep the height of the adhesive film on the side vertical surface at 1 - 2 mm;

[0057] (VI) Placing the blade panel

[0058] Use a vacuum suction cup to hold both ends of the blade panel and place it vertically in the corresponding area of the blade body, so that the blade panel evenly sinks into the blade body, the positions of the blade panel and the blade body correspond, and the bonding area 2 of Part 1 is within the coverage of the blade panel;

[0059] (VII) Placing the adhesive film

[0060] Cut the high-temperature curing adhesive film into strips about 3 mm wide and cover the gap between the blade panel and Part 1;

[0061] (VIII) Placing the uniform pressure plate tooling 3

[0062] First place a non-porous isolation film to cover the blade panel, and then place the uniform pressure plate tooling 3. The edge of the uniform pressure plate tooling 3 is flush with the blade panel. The size and contour of the bonding area 2 of the uniform pressure plate tooling 3 are the same as that of Part 1. The uniform pressure plate tooling 3 is made of high-temperature resistant rubber material. The uniform pressure plate tooling 3 is located above the blade body, and the blade body is arranged between the uniform pressure plate tooling 3 and Part 1. There are two lifting ring through holes 4 above the uniform pressure plate tooling 3;

[0063] (IX) Making the high-temperature vacuum bag 5

[0064] A high-temperature vacuum bag 5 is made on the surface of the blade body, evacuated, and the airtightness of the vacuum bag is detected. Load point thermocouples 7 are placed at both ends of the blade. There are two vacuum nozzles 6 on the high-temperature vacuum bag 5. There are two thermocouples 7, which are respectively located at both ends of the high-temperature vacuum bag 5. The two vacuum nozzles 6 are also respectively located at both ends of the high-temperature vacuum bag 5, and there is a spacing from the corresponding thermocouples 7 respectively;

[0065] (X) Autoclave curing

[0066] Place the part 1 with the vacuum bag made in the autoclave, and start the program to heat and pressurize the part 1 for curing;

[0067] (XI) Demolding

[0068] Take out the cured part 1 from the autoclave, remove the vacuum bag, and take out the equalizing plate tooling 3.

[0069] In summary, the present invention has high processing efficiency, improves the bonding quality, solves the problems of debonding and uneven adhesive layer thickness in the bonding of the thin-walled panel of the hollow blade, and has the advantages of saving manpower and material resources and being suitable for large-scale production.

[0070] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. A hollow blade manufacturing process including a gluing process, characterized in that: The steps include: S1. Film construction Laying a high temperature curing structural adhesive film on the bonding area (2) of the part (1) and performing a preheating treatment to remove bubbles; S2. Place the blade panel Use vacuum suction cups to hold both ends of the blade panel vertically and place them in the corresponding areas of the blade body, so that the blade panel is evenly sunken into the blade body; S3. Place the film Cut the high temperature curing adhesive film into thin strips of about 3 mm to cover the gap between the blade panel and the part (1); S3. Place the pressure plate tooling (3) First, place a non-porous isolation film to cover the blade panel, and then place a pressure equalizing plate tooling (3), with the edge of the pressure equalizing plate tooling (3) flush with the blade panel; S4. Making high temperature vacuum bags (5) A high-temperature vacuum bag (5) is made on the surface of the blade body, vacuuming and testing the air tightness of the vacuum bag, and load point thermocouples (7) are placed at both ends of the blade; S5, Autoclave Curing The vacuum bagged part (1) is placed in an autoclave, and a program is started to heat and pressurize the part (1) for curing; S6, demoulding The cured part (1) is taken out from the autoclave, the vacuum bag is removed, and the pressure plate tooling (3) is taken out; In the step S1, a high-temperature curing adhesive film is laid on the bonding area (2) of the part (1), and a high-temperature vacuum bag (5) is made to vacuum and compress the adhesive film to remove internal bubbles between the adhesive film and the blade body. The R area and the side edge area are pressed with a smooth scraper to prevent the high-temperature curing structural adhesive film from bridging to form a void area. After pre-evacuation for 10 minutes, the adhesive film is preheated at 40 to 50° C. with a hot air gun to increase the viscosity of the adhesive film and the surface of the part (1) to prevent the adhesive film from moving or local wrinkles and bubbles from occurring during the removal of the vacuum bag for subsequent operations.

2. A hollow blade manufacturing process including a gluing step as claimed in claim 1, characterized in that: In the step S1, the part (1) is cleaned before gluing, the surface to be bonded and the bonding surface of the tooling of the part (1) are cleaned with acetone, and then naturally dried.

3. A hollow blade manufacturing process including a gluing step as claimed in claim 2, characterized in that: In the step S1, the part (1) is surface treated after being cleaned, the body of the part (1) is anodized with phosphoric acid, and a corrosion-inhibiting primer is applied.

4. A hollow blade manufacturing process including a gluing step as claimed in claim 1, characterized in that: In the step S1, the adhesive film is cut according to the shape of the workpiece, and the adhesive film is 3 to 5 mm larger than the adhesive area (2) of the part (1).

5. A hollow blade manufacturing process including a gluing step as claimed in claim 4, characterized in that: In the step S2, before placing the blade panel, the excess adhesive film is cut off along the edge of the bonding area of ​​the blade body, and the adhesive film is retained at a height of 1 to 2 mm on the side surface.

6. A hollow blade manufacturing process including a gluing step as claimed in claim 1, characterized in that: In the step S2, the positions of the blade panel and the blade body correspond, and the bonding area (2) of the part (1) is located within the coverage of the blade panel.

7. A hollow blade manufacturing process including a gluing step as claimed in claim 6, characterized in that: In the step S4, the pressure equalizing plate fixture (3) has the same size and contour as the bonding area (2) of the part (1), and the pressure equalizing plate fixture (3) is made of high-temperature resistant rubber material.

8. A hollow blade manufacturing process including a gluing step as claimed in claim 1, characterized in that: In the step S4, the pressure equalizing plate fixture (3) is located above the blade body, the blade body is arranged between the pressure equalizing plate fixture (3) and the part (1), and two lifting ring through holes (4) are arranged above the pressure equalizing plate fixture (3).

9. A hollow blade manufacturing process including a gluing step as claimed in claim 8, characterized in that: In step S5, the high-temperature vacuum bag (5) is provided with two vacuum nozzles (6), and there are two thermocouples (7), which are respectively located at two ends of the high-temperature vacuum bag (5). The two vacuum nozzles (6) are also respectively located at two ends of the high-temperature vacuum bag (5) and are spaced apart from the corresponding thermocouples (7).

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