Automatic laying forming method for thermoplastic composite material fan blade

Abstract

The invention belongs to the technical field of composite material aero-engine fan blade forming, and particularly relates to an automatic laying forming method of a thermoplastic composite material fan blade, and a forming system is composed of a calculation and control system, a thermoplastic composite material automatic fiber laying machine, a structured light scanner and a laser projector. The blade basin part, the blade back part and the tenon part of the thermoplastic composite material fan blade are respectively and automatically laid and formed by utilizing the forming system, and then are placed in a mould pressing mould to be subjected to hot press forming to obtain the thermoplastic composite material fan blade. According to the laying and forming system and method, the problems that in the automatic laying and forming process of the complex curved surface of the thermoplastic composite material fan blade, due to the fact that the blade tenon part is large in thickness and transition is fast from thick to thin, laying and forming are difficult, and the technology is complex are solved. The problem that when a + 45-degree or-45-degree middle laying layer is laid, redundant laying materials affect the blade profile precision of the blade is solved.

Description

Technical Field The present invention relates to the technical field of thermoplastic composite fan blades, and in particular to an automatic placement and molding method for thermoplastic composite fan blades. Background Art The automated placement robot needs to cut the prepreg tow after placement. However, due to space limitations within the placement head, the cutter is typically positioned a certain distance from the placement rollers. This distance is the automated placement machine's minimum placement distance, typically ranging from 50-200mm. Due to this minimum placement distance, a section of prepreg tow always remains between the rollers and the cutter during placement. This section of prepreg tow is the same length as the minimum placement distance.

[0001] Due to the existence of the minimum laying distance, when laying +45° or -45° layers in right-angle or rounded corner areas, the required laying length is less than the minimum laying distance, resulting in over-laying. Composite fan blades are mainly subjected to centrifugal force during operation, so according to the mechanical performance design requirements, the layers are mainly [0° / +45° / 0° / -45°]ns layers. In addition, due to the variable thickness structure of the fan blade, the layer size needs to change gradually, so when laying +45° or -45° layers, there is always excess material in the corners of the middle small layer. If this part of the excess material is not removed, it will affect the blade shape of the final fan blade and thus affect its aerodynamic characteristics.

[0002] In addition, during the automatic placement and molding process of thermoplastic composite fan blades, the error between the actual placement thickness and the theoretical thickness increases with the number of layers laid, resulting in a large placement deviation when planning the placement path according to the initial digital model.

[0003] The present invention provides an automatic placement and molding system for thermoplastic composite fan blades. The system solves the placement deviation problem caused by thickness variation by regenerating a new plane through the combination of a wire placement machine with structured light scanning equipment, a laser projector, etc., and solves the problem of +45° or -45° placement by manually removing the positioning by the equipment. Summary of the Invention Aiming at the technical deficiencies of existing automatic wire placement forming technology for thermoplastic composite fan blades, the present invention proposes an automatic placement forming system and forming method for thermoplastic composite fan blades.

[0004] In order to achieve the above object, the present invention is implemented through the following technical solutions: A thermoplastic composite fan blade automatic placement molding system, the molding system consists of a computing and control system 1, a thermoplastic composite automatic wire placement machine 2, a structured light scanner 3, and a laser projector 4; the thermoplastic composite automatic wire placement machine 2, the structured light scanner 3, and the laser projector 4 are respectively connected to the computing and control system 1; the thermoplastic composite automatic wire placement machine 2 is used to automatically place and mold thermoplastic composite prepreg tapes and / or prepreg yarns; during placement, the laser projector 4 first projects the current lay-up range and fiber direction on the mold surface, and then the thermoplastic composite automatic wire placement machine 2 starts to lay the thermoplastic composite prepreg tapes and / or prepreg yarns. After laying a certain number of layers, the structured light scanning device 3 is used to scan the partially laid fan blade structure and store it in the computing and control system 1. A new plane is formed by calculation and fitting, and then the plane is extracted and path planning is re-performed based on it.

[0005] A method for molding a thermoplastic composite fan blade. The automatic placement molding system molds the thermoplastic composite fan blade according to the following steps: Step 1: Paste a thermoplastic polymer film on the surface of the blade laying and forming mold 6, and then use the thermoplastic composite material automatic fiber laying machine 2 to lay the back part preform of the thermoplastic composite material blade on the surface of the thermoplastic polymer film according to the designed laying and sequence; when laying, the laser projector 4 first projects the current laying range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber laying machine 2 starts to lay the thermoplastic prepreg bundle. When the laying is 0°, it is laid normally; when the laying is +45° or -45°, place an auxiliary template outside the laser projection area and fix it with high-temperature tape, and then the thermoplastic composite material automatic fiber laying machine 2 starts to lay the thermoplastic prepreg bundle. The composite material automatic laying machine 2 lays the prepregs normally, cuts off the extra prepregs along the projection curve of the laser projector 4, removes the auxiliary template and starts laying the next layer; after laying 12-50 layers, a target sticker is affixed to the surface of the laid preform, and then the structured light scanner 3 is turned on to scan and generate a two-dimensional plane with spatial coordinates. The plane is fitted and repaired as the reference plane, and then a new path planning and collision simulation are carried out on it, and laying is started according to the new path; a new reference plane is regenerated every 12-50 layers, and laying is carried out on the basis of the new plane until the laying of the blade back preform is completed; Step 2: Lay out a blade basin preform of the thermoplastic composite material blade on the surface of the blade lay-up molding lower mold 5 in the same manner as in step 1; Step 3: Obtain a blade tenon preform by automatic placement or manual placement; Step 4: The preforms obtained in the first three steps are combined in the order of the blade basin part 9, the tenon part 8 and the blade back part 7 and placed in a thermoplastic composite fan blade forming mold for hot pressing. After machining to remove the process edge and bonding the metal edging, a thermoplastic composite fan blade is obtained.

[0006] The thermoplastic polymer film is one of polyetherimide PEI, polyethersulfone PES, and polyaryletherketone PAEK.

[0007] The thickness of the thermoplastic polymer film is 0.05-0.8 mm.

[0008] In step 1, before pasting the thermoplastic polymer film, the thermoplastic polymer film is first placed on the surface of the blade laying molding mold, and then the PI film is fixed with a magnet to make it fit with the mold surface, the surface wrinkles are cut off and the cut gaps are pasted with PI tape, and the spliced ​​PI film is pasted and fixed to the surface of the blade laying molding mold with high-temperature resistant double-sided tape.

[0009] When laying +45° layers or -45° layers, a laser projector is used to project the laying area of ​​the current layer onto the blade laying molding mold or the surface of the laid fan blade. When the length of the laying area is greater than or equal to the minimum laying distance of the thermoplastic composite material automatic laying machine, the laying machine is used normally. When the length of the laying area is less than the minimum laying distance of the thermoplastic composite material automatic laying machine, the laying machine is stopped and manual laying is performed according to the laser projection area.

[0010] The auxiliary template is one of a thermoplastic polymer film, a release paper, and a metal sheet layer.

[0011] The preparation method of the auxiliary template comprises the following steps: manually cutting a film with a thickness of 0.05-0.8 mm by laser cutting or an automatic blanking machine to form an auxiliary template with a corresponding leaf shape missing in the middle.

[0012] The hot pressing method of step 4 is as follows: placing the preforms of the blade basin part 9, the tenon part 8 and the blade back part 7 on the corresponding mold, and then packaging them according to PI film, high-temperature demoulding cloth, high-temperature glass breathable felt, and PI film vacuum bag. After vacuuming, they are placed in a high-temperature and high-pressure autoclave, and hot pressed at a temperature of 360-400°C and a pressure of 1.5-2.5MPa for 0.5-2.0h, and then cooled and taken out of the autoclave.

[0013] When the blade basin part 9, the tenon part 8 and the blade back part 7 are assembled and placed in sequence in step 4, the assembly surface needs to be polished rough, wiped clean, and then a resin film or resin mesh with a thickness of 0.05-0.5mm, the same as the resin in the fan blade, is placed on the assembly surface.

[0014] The present invention proposes an automated placement and molding system based on a combination of a thermoplastic composite automatic fiber placement machine, a structured light scanner, and a laser projector. The various devices in this combined system are interconnected via a computing and control system. The thermoplastic composite automatic fiber placement machine is used to automatically lay thermoplastic composite prepreg tapes or filaments on a blade forming mold. After laying a certain number of layers, a structured light scanner is used to scan the portion of the blade structure laid on the mold and store it in a computer. A new plane is formed through computational fitting, and its Z-axis coordinate information is completely consistent with the actual required coordinates. This plane is then extracted and used as a basis for re-planning the path.

[0015] Compared with the existing technology, the advantages of the present invention are: (1) it solves the problem of difficult and complicated laying and forming process of the blade tenon part due to its large thickness and rapid transition from thick to thin during the automatic laying and forming of the complex curved surface of thermoplastic composite fan blades; (2) at the same time, due to the presence of a large number of small layers in the blade tenon part, it would waste a lot of time to lay this part by machine. It can be accurately positioned by laser projection and then manually laid using an ultrasonic welder or electric soldering iron, which can further improve efficiency. (3) When laying the +45° or -45° middle layer, the excess laying material will be laid on the template without bonding with the prepreg already laid on the bottom layer. The excess material can be easily cut off, thereby achieving accurate laying of the +45° or -45° layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the composition of an automatic placement and molding system for thermoplastic composite fan blades of the present invention.

[0017] The meaning of the marks in the figure: 1. Computing and control system, 2. Automatic fiber placement machine for thermoplastic composite materials, 3. Structured light scanner, 4. Laser projector, 5. Lower mold for blade placement and molding, 6. Upper mold for blade placement and molding.

[0018] Figure 2 This is a schematic diagram of a thermoplastic composite fan blade of the present invention being split into three components.

[0019] The meaning of the marks in the figure: 7. Leaf back, 8. Tenon, 9. Leaf basin Figure 3 This is a flow chart of an automatic placement and molding method for a thermoplastic composite fan blade according to the present invention. DETAILED DESCRIPTION

[0020] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings of the present invention: Example 1 See also Figures 1 to 3 In this embodiment, a thermoplastic composite fan blade automatic placement molding system and molding method, the automatic placement molding system (see Figure 1 ) consists of a computing and control system 1, a thermoplastic composite material automatic fiber placement machine 2, a structured light scanner 3, and a laser projector 4. The automatic placement molding system is used to automatically place and mold thermoplastic composite material fan blades (see Figure 2 ) molding method (see Figure 3 ) The steps are as follows: Aimed at the molding of carbon fiber reinforced polyaryletherketone resin (CF / PEEK) composite fan rotor blades.

[0021] First, a 0.05mm thick PI film is placed on the surface of the blade laying and forming upper mold 6, and then the PI film is fixed with a magnet to make it fit the mold surface. The surface wrinkles are cut off and the cut gaps are sealed with PI tape. The spliced ​​PI film is fixed to the surface of the blade laying and forming upper mold 6 with high-temperature resistant double-sided tape. Then, a thermoplastic composite material automatic fiber laying machine 2 is used to lay the blade basin part 9 preform of the thermoplastic composite material blade on the surface of the glued PI film according to the designed layer and sequence. When laying, the computing and control system 1, the thermoplastic composite material automatic fiber laying machine 2, the structured light scanner 3, and the laser projector 4 are first connected and started. According to the layer plan, the laser projector 4 first projects the current layer range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber laying machine 2 starts to lay the CF / PEEK prepreg bundle. When the layup angle is 0°, normal layup is performed without any additional processing. However, when the layup angle is +45° or -45°, an automatic blanking machine is used to pre-cut a 0.05mm thick PI film to form an auxiliary template with the corresponding blade shape missing in the middle. This auxiliary template is then placed outside the laser projection area and secured with high-temperature PI tape to block the area where excess material will be laid. The thermoplastic composite automatic fiber placement machine 2 is then used for normal layup. Afterwards, an electric scissor is used to cleanly cut the excess prepreg tows along the curve projected by the laser projector 4. The auxiliary template is then removed and the next layer is laid.

[0022] After 12 layers have been laid, the maximum thickness of the preform reaches approximately 2mm. Target stickers are then applied to the surface of the preform. A structured light scanner 3 is then used to scan and generate a two-dimensional plane containing spatial coordinates. This plane is then fitted and patched, used as the reference plane for new path planning and collision simulation. Laying begins along this new path. A new reference plane is generated every 12-30 layers, and laying continues based on this new plane until the blade back preform is completely laid.

[0023] The upper blade placement mold 6 and the blade back preform are then removed and replaced with the lower blade placement mold 5 to begin placing the blade base preform. The placement method is the same as for the blade back preform. After the blade back and blade base are laid, the tenon preform is manually laid using the laser projection of the laser projector 4.

[0024] The preforms of the blade basin 9, tenon 8, and blade back 7 obtained above are placed on the corresponding layup molds. They are then packaged with PI film, high-temperature release cloth, high-temperature glass breathable felt, and PI film vacuum bags. The preforms are then vacuumed and placed in a high-temperature, high-pressure autoclave at 380°C and 2MPa for 1 hour. The preforms are then cooled and removed from the autoclave. The assembled surfaces of the blade basin 9, tenon 8, and blade back 7 components are roughened with sandpaper, then wiped clean with acetone and allowed to dry. A 0.2mm thick PEEK resin film is then placed on the bonding surfaces. The preforms are then assembled in sequence and placed in a thermoplastic composite fan blade molding die, where they are hot-pressed at 380°C and 20MPa for 2 hours. The preforms are then cooled and removed from the mold. The blade blanks are then machined to remove the edge, and finally bonded with metal edging to obtain thermoplastic CF / PEEK composite fan blades.

[0025] Example 2 See also Figures 1 to 3 In this embodiment, a thermoplastic composite fan blade automatic placement molding system and molding method, the automatic placement molding system (see Figure 1 ) consists of a computing and control system 1, a thermoplastic composite material automatic fiber placement machine 2, a structured light scanner 3, a laser projector 4, a blade placement molding lower mold 5 and a blade placement molding upper mold 6. The automatic placement molding system is used to automatically place and mold thermoplastic composite fan blades (see Figure 2 ) molding method (see Figure 3 ) The steps are as follows: Aimed at the molding of carbon fiber reinforced polyetherketoneketone resin (CF / PEKK) composite fan rotor blades.

[0026] First, a 0.1mm thick PEI film is placed on the surface of the lower mold 5 for blade laying and molding. Then, the PI film is fixed with a magnet and heated with a hot air gun to make it fit the mold surface. The surface wrinkles are cut off and the slits are glued with PI tape. The spliced ​​PI film is glued and fixed to the surface of the lower mold 5 for blade laying and molding with high-temperature resistant double-sided tape. Then, a thermoplastic composite material automatic fiber laying machine 2 is used to lay the blade basin part 9 preform of the thermoplastic composite blade on the surface of the glued PEI film according to the designed layer and sequence. When laying, the computing and control system 1, the thermoplastic composite material automatic fiber laying machine 2, the structured light scanner 3, and the laser projector 4 are first connected and started. According to the layer plan, the laser projector 4 first projects the current layer range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber laying machine 2 begins to lay the CF / PEKK prepreg tow. When the layup angle is 0°, normal layup is performed without additional processing. However, when the layup angle is +45° or -45°, a 0.2mm thick release paper is pre-cut using an automatic blanking machine to form an auxiliary template with the corresponding leaf shape missing in the middle. This auxiliary template is then placed outside the laser projection area and secured with paper tape to block the area where excess material will be laid. The thermoplastic composite automatic filament placement machine 2 then operates normally for layup. The excess prepreg tows are then cleanly cut using electric shears along the curve projected by the laser projector 4. The release paper template is then removed and the next layer of material is laid.

[0027] After 20 layers of plywood were laid, the maximum thickness of the preform reached approximately 3mm. Target stickers were then applied to the surface of the preform. A structured light scanner 3 was then used to scan and generate a two-dimensional plane containing spatial coordinates. This plane was then fitted and patched, used as the reference plane. New path planning and collision simulation were then performed on this plane, and then placement began along the new path. A new reference plane was generated every 20 layers, and placement continued based on this new plane until the entire blade basin preform was completely laid.

[0028] The lower blade placement mold 5 and the blade back preform are then removed and replaced with the upper blade placement mold 6 to begin placing the blade back preform. The placement method is the same as for the blade base preform. After the blade back and blade base are placed, the tenon preform is manually laid using the laser projection of the laser projector 4.

[0029] The preforms of the blade basin 9, tenon 8, and blade back 7 obtained above are placed on the corresponding layup molds. They are then packaged with a PI film coated with a high-temperature release agent, a high-temperature release cloth, and a PI film vacuum bag. The preforms are then vacuum-baked and placed in a high-temperature, high-pressure autoclave at 360°C and 2MPa for 1 hour. The preforms are then cooled and removed from the autoclave. The surfaces of the blade basin 9, tenon 8, and blade back 7 components are sanded to remove the surface release agent, then wiped clean with acetone and allowed to dry. A 0.05mm thick PEKK resin film is then placed on the bonding surfaces. The preforms are then assembled in sequence and placed in a thermoplastic composite fan blade molding die. The preforms are then hot-pressed at 360°C and 10MPa for 1.5 hours. The preforms are then cooled and removed from the molds. The blade blanks are then machined to remove the edge finish and bonded with metal edging to produce a thermoplastic CF / PEKK composite fan blade.

[0030] Example 3 See also Figures 1 to 3 In this embodiment, a thermoplastic composite fan blade automatic placement molding system and molding method, the automatic placement molding system (see Figure 1 ) consists of a computing and control system 1, a thermoplastic composite material automatic fiber placement machine 2, a structured light scanner 3, a laser projector 4, a blade placement molding lower mold 5 and a blade placement molding upper mold 6. The automatic placement molding system is used to automatically place and mold thermoplastic composite fan blades (see Figure 2 ) molding method (see Figure 3 ) The steps are as follows: Aimed at the molding of carbon fiber reinforced polyaryletherketone resin (CF / PAEK) composite fan rotor blades.

[0031] First, a 0.1mm thick PI film is placed on the surface of the lower mold 5 for blade laying and molding. The PI film is then fixed with a magnet and heated with a hot air gun to fit it to the mold surface. Surface wrinkles are cut off and the slits are glued with PI tape. The spliced ​​PI film is then glued and fixed to the surface of the lower mold 5 for blade laying and molding with high-temperature resistant double-sided tape. Then, a thermoplastic composite material automatic fiber placement machine 2 is used to lay the blade basin part 9 preform of the thermoplastic composite blade on the surface of the glued PI film according to the designed layup and sequence. When laying, the computing and control system 1, the thermoplastic composite material automatic fiber placement machine 2, the structured light scanner 3, and the laser projector 4 are first connected and started. According to the layup plan, the laser projector 4 first projects the current layup range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber placement machine 2 begins to lay the CF / PAEK prepreg tow. When the layup is 0°, it is laid normally and no additional processing is required; however, when the layup is +45° or -45°, a laser projector is used to project the laying area of ​​the current layup on the blade laying and molding mold 5 or 6 or the surface of the laid fan blade. When the length of the laying area is greater than or equal to the minimum laying distance of the thermoplastic composite material automatic laying machine 2, the laying machine is used normally. When the length of the laying area is less than the minimum laying distance of the thermoplastic composite material automatic laying machine 2, the laying machine is stopped and the layers are manually laid and cut according to the laser projection area using an ultrasonic spot welder, an electric soldering iron or a hot air gun.

[0032] After 40 layers were laid, the maximum thickness of the preform reached approximately 5.7mm. Target stickers were affixed to the surface of the preform. A structured light scanner 3 was then used to scan and generate a two-dimensional plane containing spatial coordinates. This plane was then fitted and patched, serving as the reference plane for new path planning and collision simulation. Afterward, placement began along the new path. A new reference plane was generated every 40 layers, and placement continued based on this new plane until the entire blade basin preform was completely laid.

[0033] The lower blade placement mold 5 and the blade back preform are then removed and replaced with the upper blade placement mold 6 to begin placing the blade back preform. The placement method is the same as for the blade base preform. After the blade back and blade base are placed, the tenon preform is manually laid using the laser projection of the laser projector 4.

[0034] The preforms of the blade basin 9, tenon 8, and blade back 7 obtained above are placed in the corresponding layup molds. The preforms are then packaged with a PI film coated with a high-temperature release agent, a high-temperature glass felt, and a PI film vacuum bag. The preforms are then vacuum-baked and placed in a high-temperature, high-pressure autoclave at 360°C and 2 MPa for 1 hour. The autoclave is then cooled and removed. The surfaces of the assembly of the blade basin 9, tenon 8, and blade back 7 are sanded to remove the surface release agent, then cleaned with acetone and allowed to dry. A 0.3mm thick PEKK resin mesh is then placed on the bonding surfaces. The preforms are then assembled in the order shown and placed in a thermoplastic composite fan blade molding die. The preforms are then hot-pressed at 360°C and 10 MPa for 2 hours. The preforms are then cooled and removed from the mold. The blade blanks are then machined to remove the edge finish and bonded to a metal cladding to produce a thermoplastic CF / PAEK composite fan blade.

[0035] Compared with the prior art, the present invention is beneficial in that: (1) it solves the problem of difficulty in laying and forming the blade tenon portion 8 and the complexity of the process caused by the large thickness and rapid transition from thick to thin during the automatic laying and forming of the complex curved surface of the thermoplastic composite fan blade; (2) at the same time, since the blade tenon portion 8 has a large number of small layers of intercalated structure, it would waste a lot of time to lay this part of the layer by machine. It can be accurately positioned by laser projection and then manually laid using an ultrasonic welder or electric soldering iron, which can further improve efficiency. (3) When laying the +45° or -45° middle layer, the excess laying material will be laid on the template without bonding with the prepreg already laid on the bottom layer. The excess material can be easily cut off, thereby achieving accurate laying of the +45° or -45° layer.

Claims

1. An automatic placement molding system for thermoplastic composite fan blades, characterized in that: The molding system consists of a computing and control system (1), a thermoplastic composite material automatic fiber placement machine (2), a structured light scanner (3), and a laser projector (4); the thermoplastic composite material automatic fiber placement machine (2), the structured light scanner (3), and the laser projector (4) are respectively connected to the computing and control system (1); the thermoplastic composite material automatic fiber placement machine (2) is used to automatically lay out the thermoplastic composite material prepreg tape or prepreg yarn; when laying, the laser projector (4) first projects the current laying range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber placement machine (2) starts to lay the thermoplastic composite material prepreg tape or prepreg yarn. After laying 12-50 layers, the structured light scanning device (3) is used to scan the partially laid fan blade structure and store it in the computing and control system (1). A new plane is formed by calculation fitting, and then the plane is extracted and the path planning is re-performed based on it.

2. A method for molding a thermoplastic composite fan blade, characterized in that: The thermoplastic composite fan blade is formed by the automatic placement molding system according to claim 1 according to the following steps: Step 1: A thermoplastic polymer film is pasted on the surface of the blade laying mold (6), and then a thermoplastic composite material automatic fiber laying machine (2) is used to lay the back part preform of the thermoplastic composite blade on the surface of the thermoplastic polymer film according to the designed laying and sequence; when laying, the laser projector (4) first projects the current laying range and fiber direction on the mold surface, and then the thermoplastic composite material automatic fiber laying machine (2) starts to lay the thermoplastic prepreg bundle. When the laying is 0°, it is laid normally; when the laying is +45° or -45°, an auxiliary template is placed outside the laser projection area and fixed with high-temperature tape, and then the thermoplastic The composite material automatic laying machine (2) lays the prepregs in normal manner, cuts the extra prepregs along the projection curve of the laser projector (4), removes the auxiliary template, and starts laying the next layer; after laying 12-50 layers, a target sticker is affixed to the surface of the laid preform, and then the structured light scanner (3) is turned on to scan and generate a two-dimensional plane containing spatial coordinates, and the plane is fitted and repaired as a reference plane, and then a new path planning and collision simulation are carried out on it, and laying is started according to the new path; a new reference plane is regenerated every 12-50 layers, and laying is carried out on the basis of the new plane until the laying of the blade back preform is completed; Step 2: laying out a blade basin preform of the thermoplastic composite material blade on the surface of the blade laying molding lower mold (5) in the same manner as in step 1; Step 3: Obtain a blade tenon preform by automatic placement or manual placement; Step 4: The preforms obtained in the first three steps are placed in the order of the blade basin part (9), the tenon part (8) and the blade back part (7) in a thermoplastic composite fan blade forming mold for hot pressing, and the thermoplastic composite fan blade is obtained after machining to remove the process edge and bonding the metal edging.

3. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: The thermoplastic polymer film is one of polyetherimide PEI, polyethersulfone PES, and polyaryletherketone PAEK.

4. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: The thickness of the thermoplastic polymer film is 0.05-0.8 mm.

5. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: In step 1, before pasting the thermoplastic polymer film, the thermoplastic polymer film is first placed on the surface of the blade laying molding mold, and then the PI film is fixed with a magnet to make it fit with the mold surface, the surface wrinkles are cut off and the cut gaps are pasted with PI tape, and the spliced ​​PI film is pasted and fixed to the surface of the blade laying molding mold with high-temperature resistant double-sided tape.

6. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: When laying +45° layers or -45° layers, a laser projector is used to project the laying area of ​​the current layer onto the blade laying molding mold or the surface of the laid fan blade. When the length of the laying area is greater than or equal to the minimum laying distance of the thermoplastic composite material automatic laying machine, the laying machine is used normally. When the length of the laying area is less than the minimum laying distance of the thermoplastic composite material automatic laying machine, the laying machine is stopped and manual laying is performed according to the laser projection area.

7. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: The auxiliary template is one of a thermoplastic polymer film, a release paper, and a metal sheet layer.

8. The method for forming a thermoplastic composite fan blade according to claim 2, wherein: The preparation method of the auxiliary template comprises the following steps: manually cutting a film with a thickness of 0.05-0.8 mm by laser cutting or an automatic blanking machine to form an auxiliary template with a corresponding leaf shape missing in the middle.

9. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: The hot pressing method of step 4 is as follows: placing the preforms of the blade basin part (9), the tenon part (8) and the blade back part (7) on the corresponding mold, and then packaging them according to PI film, high-temperature demoulding cloth, high-temperature glass breathable felt, and PI film vacuum bag, and placing them in a high-temperature and high-pressure autoclave after vacuuming, hot pressing at a temperature of 360-400°C and a pressure of 1.5-2.5MPa for 0.5-2.0h, and then cooling them out of the autoclave.

10. The method for forming a thermoplastic composite fan blade according to claim 2, characterized in that: When the blade basin part (9), the tenon part (8) and the blade back part (7) are assembled and placed in sequence in step 4, the assembly surface needs to be polished and roughened, and then a resin film or resin mesh with a thickness of 0.05-0.5 mm, which is the same as the resin in the fan blade, is placed on the assembly surface after being wiped clean.

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