Housing, aeroengine, manufacturing method of housing and forming die

Abstract

The present disclosure provides a casing, an aeroengine, a manufacturing method of the casing, and a forming die. The casing includes a main body and holes provided on the main body. The main body includes a composite material layer, and the composite material layer includes a matrix material and a fiber preform made of fibers. Among them, some of the fibers include avoidance segments that bypass the holes. The aeroengine includes the casing. The manufacturing method of the casing includes: making a fiber preform with fibers, including making the avoidance segments of some of the fibers bypass the positions corresponding to the holes; making a composite material layer with the matrix material and the fiber preform to form the casing. The forming die of the casing includes: a core die; a first outer die; and a second outer die, where the first outer die includes a first protrusion corresponding to the position of the connection hole and adapted to the shape of the connection hole, and / or, the core die includes a second protrusion corresponding to the position of the accommodation hole and adapted to the shape of the accommodation hole. The present disclosure is beneficial to improving the mechanical properties and reliability of the casing.

Description

Technical Field

[0001] The present disclosure relates to the technical field of aero-engine manufacturing, and particularly to a casing, an aero-engine, a manufacturing method of the casing, and a forming die. Background Art

[0002] There are a large number of high-speed rotating blades in the casings of aero-engines and gas turbines. In the case of foreign object impact, process defects, etc., the rotating blades may fall off, which requires the casing to have good containment performance to ensure that the high-speed and high-energy blade fragments do not penetrate the casing and cause damage to equipment and personnel. After the blades fly off, the rotor has a huge unbalanced load, which will cause continuous vibration of the rotor before stopping. During this period, it is still required that the casing does not disintegrate and maintains a certain structural integrity.

[0003] Due to the large size of the aero-engine casing, its weight will have a significant impact on the total weight of the engine, and thus affect the engine efficiency. For this reason, fiber-reinforced composite materials are generally used for the low-temperature end casings in new-generation commercial aero-engines. For composite casings, in order to ensure high mechanical properties and reliability, it is generally desired that both the axial fibers and the circumferential fibers are continuous, that is: axially, the fibers can continuously pass through the casing body from one end flange to the other end flange; circumferentially, the fibers continuously cover the entire circumference.

[0004] The casing body is generally of a cylindrical structure. Flanges are provided at both axial ends of the cylindrical structure of the casing body. A plurality of connection holes are opened on the flanges, and the flanges are fixed to other structures of the aero-engine through connecting members. In addition, holes are also opened on the casing body to place sensors or other functional elements required for controlling the aero-engine. In the related technologies known to the inventors, the general processing method for holes on composite casings is: first, the casing is integrally formed, and then material removal methods such as machining (such as drilling) are used to process holes on the flanges or the casing body. Summary of the Invention

[0005] A first aspect of the present disclosure provides a casing, including a main body and holes provided on the main body. The main body includes a composite material layer, and the composite material layer includes a matrix material and a fiber preform made of fibers. Among them, some of the fibers include avoidance segments that bypass the holes.

[0006] According to some embodiments of the present disclosure, the main body includes:

[0007] a casing body; and

[0008] flanges located at both ends of the casing body;

[0009] The holes include connection holes provided on the flanges and / or accommodation holes provided on the casing body.

[0010] According to some embodiments of the present disclosure, the casing further includes a bushing disposed on the inner wall of the hole.

[0011] According to some embodiments of the present disclosure, the main body further includes a metal layer.

[0012] A second aspect of the present disclosure provides an aeroengine, including the casing described in the first aspect of the present disclosure.

[0013] A third aspect of the present disclosure provides a manufacturing method of the casing described in the first aspect of the present disclosure, including:

[0014] Manufacturing the fiber preform using fibers, including bypassing the corresponding position of the hole with the avoidance section of some of the fibers; and

[0015] Manufacturing a composite material layer using the matrix material and the fiber preform to form the casing.

[0016] According to some embodiments of the present disclosure, the main body includes a casing body and flanges located at both ends of the casing body. Manufacturing the fiber preform using fibers includes:

[0017] Providing the fibers;

[0018] Providing a forming mold, including providing a core mold and a first outer mold of the mold body;

[0019] Manufacturing the fiber preform of the casing body on the circumferential outer side of the core mold using the fibers;

[0020] Sheathing the first outer mold on the outer side of the fiber preform of the casing body; and

[0021] Manufacturing the fiber preform of the flange on the axial end face outer side of the first outer mold using the fibers.

[0022] According to some embodiments of the present disclosure,

[0023] The hole includes a connection hole provided on the flange. Providing the forming mold further includes providing a protrusion. The protrusion includes a first protrusion provided at a position corresponding to the connection hole on the first outer mold and adapted to the shape of the connection hole. Manufacturing the fiber preform of the flange on the axial end face outer side of the first outer mold using the fibers includes: bypassing the first protrusion with the avoidance section of some of the fibers; and / or

[0024] The hole includes a receiving hole provided in the casing body. The provided forming die further includes a provided protruding portion. The protruding portion includes a second protruding portion provided on the core mold at a position corresponding to the receiving hole and adapted to the shape of the receiving hole. Manufacturing the fiber preform of the casing body using the fibers on the circumferential outer side of the core mold includes: bypassing the second protruding portion with the avoiding segments of some of the fibers.

[0025] According to some embodiments of the present disclosure, the fibers include first fibers, second fibers, and third fibers. The first fibers include a body segment, and at least some of the first fibers further include reserved segments located at both ends of the body segment.

[0026] Manufacturing the fiber preform of the casing body using the fibers on the circumferential outer side of the core mold includes: arranging the first fibers with the body segment intersecting the second fibers; and / or

[0027] Manufacturing the fiber preform of the flange using the fibers on the outer axial end face of the first outer mold includes: arranging the first fibers with the reserved segments intersecting the third fibers.

[0028] According to some embodiments of the present disclosure, bypassing the first protruding portion with the avoiding segments of some of the fibers includes: the avoiding segments of two adjacent first fibers in the same layer bypassing the first protruding portion side by side within the layer.

[0029] According to some embodiments of the present disclosure, bypassing the first protruding portion with the avoiding segments of some of the fibers includes: the avoiding segments of two adjacent first fibers in the same layer bypassing the first protruding portion stacked along the thickness direction of the fiber preform of the flange.

[0030] According to some embodiments of the present disclosure, outside the avoiding segments,

[0031] arranging the body segment of the first fibers along the axial direction of the core mold; and / or

[0032] arranging the reserved segments of the first fibers along the radial direction of the first outer mold; and / or

[0033] arranging the second fibers along the circumferential direction of the core mold; and / or

[0034] arranging the third fibers along the circumferential direction of the first outer mold.

[0035] According to some embodiments of the present disclosure, the provided forming die further includes a second outer mold for providing a mold body; manufacturing the composite material layer using the matrix material and the fiber preform includes:

[0036] Place the second outer mold on the outside of the fiber preform of the flange and form a closed cavity with the core mold and the first outer mold, and the fiber preform is located within the closed cavity;

[0037] Fill the closed cavity with the matrix material; and

[0038] Cure the matrix material and demold to form the composite material layer.

[0039] According to some embodiments of the present disclosure, the manufacturing method further includes:

[0040] Provide a bushing;

[0041] Disposably arrange the bushing on the outer wall of the first convex portion and / or the outer wall of the second convex portion; and

[0042] After manufacturing the composite material layer using the matrix material and the fiber preform, demold the bushing together with the composite material layer so that the casing includes the bushing integrally formed with the composite material layer.

[0043] According to some embodiments of the present disclosure, the manufacturing method further includes:

[0044] Provide a metal layer;

[0045] Disposably arrange the metal layer on the circumferential outside of the core mold; and

[0046] After manufacturing the composite material layer using the matrix material and the fiber preform, demold the metal layer together with the composite material layer so that the casing includes the metal layer integrally formed with the composite material layer.

[0047] The fourth aspect of the present disclosure provides a forming mold for the casing described in the first aspect of the present disclosure, including:

[0048] A mold body for forming the composite material layer; and

[0049] A convex portion, the convex portion is disposed on the mold body at a position corresponding to the hole and is adapted to the shape of the hole.

[0050] According to some embodiments of the present disclosure,

[0051] The mold body includes a core mold, a first outer mold, and a second outer mold. The core mold is configured as a mold for making the fiber preform of the casing body, the first outer mold is configured as a mold for making the fiber preform of the flange, and the second outer mold is configured to form a closed cavity required for filling the matrix material with the core mold and the first outer mold;

[0052] The protruding portion includes at least one of a first protruding portion and a second protruding portion. Among them, the first protruding portion is disposed at a position corresponding to the connection hole on the first outer mold and is adapted to the shape of the connection hole, and the second protruding portion is disposed at a position corresponding to the accommodation hole on the core mold and is adapted to the shape of the accommodation hole.

[0053] According to some embodiments of the present disclosure,

[0054] the core mold is a combined mold; and / or

[0055] the first outer mold is a combined mold.

[0056] Based on the casing, the manufacturing method of the casing, and the molding die provided by the present disclosure, some fibers of the casing include an avoidance section bypassing the hole. At a position corresponding to the hole of the casing, the fibers with the avoidance section can maintain a continuous state, which is beneficial to improving the mechanical properties around the hole of the casing, reducing the risk of structural failure of the casing, enhancing the reliability of the casing, and also beneficial to improving the processing efficiency and processing qualification rate of the casing. Applying this casing to an aeroengine can correspondingly enhance the reliability of the aeroengine.

[0057] Through the following detailed description of the exemplary embodiments of the present disclosure with reference to the accompanying drawings, other features and advantages of the present disclosure will become clear. Description of the Drawings

[0058] The accompanying drawings described herein are used to provide a further understanding of the present disclosure, and constitute a part of this application. The schematic embodiments of the present disclosure and their descriptions are used to explain the present disclosure and do not constitute an improper limitation to the present disclosure. In the drawings:

[0059] Figure 1 The cross-sectional structure of the casing according to some embodiments of the present disclosure is shown.

[0060] Figure 2 The structure of the core mold according to some embodiments of the present disclosure is shown.

[0061] Figure 3 It shows that in some embodiments of the present disclosure, a fiber preform of the casing body is made on the circumferential outer side of the core mold using fibers.

[0062] Figure 4 It shows the state where the first outer mold is sleeved on the outside of the fiber preform of the casing body in some embodiments of the present disclosure.

[0063] Figure 5 It shows the setting manner of the reserved section of the first fiber on the first outer mold when making the casing by using the hole-opening method in the related art.

[0064] Figure 6Shows the setting manner of the first fiber on the first outer mold in some embodiments of the present disclosure.

[0065] Figure 7 Shows the setting manner of the first fiber on the first outer mold in some other embodiments of the present disclosure.

[0066] Figure 8 Shows the setting manner of the third fiber on the first outer mold when manufacturing the casing by using the hole-opening method in the related art.

[0067] Figure 9 Shows the setting manner of the third fiber on the first outer mold in some embodiments of the present disclosure.

[0068] Figure 10 Shows the state in which the core mold, the first outer mold, and the second outer mold of some embodiments of the present disclosure form a closed cavity, and the state in which the fiber preform of the casing is located in the closed cavity. Detailed implementation manners

[0069] Next, the technical solutions in the embodiments of the present disclosure will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all the embodiments. The description of at least one exemplary embodiment herein is actually only illustrative and in no way limits the present disclosure and its application or use. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.

[0070] Unless otherwise specifically stated, the relative arrangements, numerical expressions, and numerical values of the components and steps described in these embodiments do not limit the scope of the present disclosure. At the same time, it should be understood that, for the sake of convenience of description, the dimensions of the various parts shown in the drawings are not drawn in actual proportional relationships. Technologies, methods, and devices known to those of ordinary skill in the relevant art may not be discussed in detail, but under appropriate circumstances, these technologies, methods, and devices should be regarded as part of the authorization specification. In all the examples shown and discussed here, any specific value should be interpreted as merely exemplary and not as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that: similar reference numerals and letters denote similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0071] In the description of the present disclosure, it should be understood that the use of words such as "first" and "second" to limit the components is only for the convenience of distinguishing the corresponding components. Without further statement, the above words have no special meanings. Therefore, it cannot be understood as a limitation to the protection scope of the present disclosure.

[0072] In the description of the present disclosure, it should be understood that the orientation or positional relationship indicated by orientation words such as "front, back, top, bottom, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom", etc. is usually based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present disclosure and simplifying the description. Without contrary description, these orientation words do not indicate and imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on the protection scope of the present disclosure; the orientation words "inside, outside" refer to the inside and outside relative to the contour of each component itself.

[0073] In the process of implementing the technical solution of the present disclosure, the inventor found that in the related art, processing the holes of the composite material casing by the method of removing materials will bring the following problems:

[0074] Removing materials causes the continuous fibers in the casing to be interrupted, and the number of continuous fibers for providing the force transmission path is reduced, resulting in the weakening of the mechanical properties around the holes. For example, processing the connection holes on the flange that bear the connection load by the method of removing materials will significantly increase the risk of structural failure of the casing and reduce the reliability of the casing.

[0075] When removing materials, additional loads are usually accompanied, such as the vibration load during drilling. These additional loads may cause the failure of the inherently weak interlayer interface in the composite material, resulting in delamination of the composite material and the scrapping of the expensive casing.

[0076] In addition, the composite material with a hybrid structure and hybrid fibers has become a new development trend of the composite material casing due to its richer designability. Since the processing properties of different types of fibers are different, if the method of removing materials is still used to open holes, it is easy to cause the processing quality of different types of fibers to be unable to be taken into account.

[0077] In order to improve the above problems, the embodiments of the present disclosure provide a casing, an aeroengine, a manufacturing method of the casing and a forming die.

[0078] The aeroengine provided by the embodiment of the present disclosure includes the casing provided by the embodiment of the present disclosure and has the advantages of the casing provided by the embodiment of the present disclosure.

[0079] The casing provided by the embodiment of the present disclosure includes a main body and holes provided on the main body. The main body includes a composite material layer, and the composite material layer includes a matrix material and a fiber preform made of fibers. Among them, some fibers include an avoidance section that bypasses the holes. For example, such as Figure 5 the avoidance section L1 shown, such as Figure 6 the avoidance section L2 shown and such as Figure 8The avoidance section L3 shown. At the position corresponding to the hole in the casing, the fibers with the avoidance section can remain continuous, which is beneficial to improving the mechanical properties around the hole of the casing, reducing the risk of structural failure of the casing, enhancing the reliability of the casing, and also beneficial to improving the machining efficiency and machining qualification rate of the casing. Applying this casing to an aeroengine can correspondingly enhance the reliability of the aeroengine.

[0080] As Figure 1 shown, the casing is a continuous structure, and the main body includes a casing body 1 and flanges 2 and 3. The flanges 2 and 3 are located at both ends of the casing body 1. In the casings of some embodiments, the holes provided on the main body include connection holes 21 and 31 provided on the flanges 2 and 3, and the connection holes are used for connecting the casing with other structures of the aeroengine. In the casings of other embodiments, the holes provided on the main body include accommodation holes provided on the casing body 1, and the accommodation holes are used for placing sensors or other functional elements required for controlling the aeroengine. In the above embodiments, the fiber preform includes continuous fibers passing through the casing body 1 from the flange 2 to the flange 3. Whether the holes provided on the main body are connection holes or accommodation holes, the continuous fibers are arranged around the contour of the holes, and a part of the continuous fibers may include an avoidance section bypassing the connection hole, and another part of the continuous fibers may include an avoidance section bypassing the accommodation hole.

[0081] According to the design requirements, the composite material layer may include at least one layer of fiber preform, for example, three layers of fiber preforms A, B, and C arranged in sequence along the thickness direction of the composite material layer. The thicknesses of each layer of fiber preform may be different, and the thicknesses of each layer of fiber preform at different positions may also be different. The fiber preform can be made by a weaving process, and the fiber preform can be a two-dimensional woven fiber preform or a three-dimensional woven fiber preform.

[0082] As Figures 2 to 10 shown, the manufacturing method of the casing provided by some embodiments of the present disclosure includes:

[0083] Step 1: Making a fiber preform with fibers, including making the avoidance section of some fibers bypass the position corresponding to the hole.

[0084] Step 2: Making a composite material layer with a matrix material and the fiber preform to form a casing.

[0085] The manufacturing method of the casing provided by the embodiments of the present disclosure can make the avoidance section of some fibers bypass the position corresponding to the hole, and has the advantages of the casing of the embodiments of the present disclosure. The following combines Figures 1 to 10 to further illustrate the manufacturing method of the casing of the embodiments of the present disclosure.

[0086] In the manufacturing method of some embodiments, for the casing having a casing body 1 and flanges 2 and 3, in step 1, making a fiber preform with fibers includes steps 1.1 to 1.5.

[0087] Step 1.1: Provide fibers.

[0088] According to the design requirements, prepare continuous fibers required for manufacturing the fiber preform. The material of the fibers can be carbon fibers, glass fibers, aramid fibers, ultra-high molecular weight polyethylene fibers, or other suitable fibers. When manufacturing the fiber preform, fibers of one or more materials can be used. For example, carbon fibers can be used alone, or carbon fibers and aramid fibers can be used simultaneously, or fibers blended with carbon fibers and aramid fibers can be used. There can also be various specifications of the fibers. When manufacturing the fiber preform, fibers of one or more specifications can be used. For example, carbon fibers of different specifications such as 6K, 12K, and 24K can be used simultaneously.

[0089] Step 1.2: Provide a molding die, including providing a core mold 6 and a first outer mold 7.

[0090] The core mold 6 is used to manufacture the fiber preform of the casing body 1. As Figure 2 、 Figure 3 and Figure 10 shown, the core mold 6 can be a cylindrical shape adapted to the inner wall shape of the casing body 1. Among them, the outer diameter of the core mold 6 is designed according to the inner diameter of the casing, and the length of the core mold 6 is designed according to the distance between the starting points of the corners of the flanges 2 and 3. Necessary process errors and curing deformation errors of the composite material are considered during the design.

[0091] The first outer mold 7 is used to manufacture the fiber preforms of the flanges 2 and 3. As Figure 4 and Figure 10 shown, the first outer mold 7 can include a cylindrical portion adapted to the outer wall shape of the casing body 1 and flanges 71 and 72 adapted to the end face shapes on the axial inner sides of the flanges 2 and 3. Among them, the inner diameter of the first outer mold 7 is designed according to the outer diameter of the casing body 1, the radii of the flanges 71 and 72 are designed according to the radii of the flanges 2 and 3, and the distance between the end faces on the axial outer sides of the flanges 71 and 72 is designed according to the distance between the starting points of the corners of the flanges 2 and 3. Necessary process errors and curing deformation errors of the composite material are considered during the design.

[0092] Step 1.3: Use fibers to manufacture the fiber preform of the casing body 1 on the circumferential outer side of the core mold 6.

[0093] In the manufacturing method of some embodiments not shown, on the basis that the casing body 1 is provided with accommodation holes, in order to facilitate the fiber with an avoidance section to bypass the position corresponding to the accommodation holes, the provided forming die further includes a protruding portion, and the protruding portion includes second protruding portions 60a, 60b, and 60c provided on the core mold 6 at positions corresponding to the accommodation holes and adapted to the shape of the accommodation holes. The sizes of the second protruding portions 60a, 60b, and 60c are determined according to the sizes of the accommodation holes, and necessary process errors and curing deformation errors of the composite material are considered during design. In step 1.3, manufacturing the fiber preform of the casing body 1 by using fibers on the outer circumference of the core mold 6 includes: making the avoidance sections of some fibers bypass the second protruding portions 60a, 60b, and 60c. When manufacturing the fiber preform of the casing body 1 in the above manner, necessary process errors and curing deformation errors of the composite material are considered.

[0094] In some embodiments, the fibers include first fibers, second fibers, and third fibers. Among them, the first fibers include a body section, and at least some of the first fibers further include reserved sections located at both ends of the body section. The body section and the reserved sections are respectively used to manufacture the fiber preform of the casing body 1 and the fiber preforms of the flanges 2 and 3. The first fibers, the second fibers, and the third fibers may all include avoidance sections.

[0095] As Figure 3 shown, in step 1.3, manufacturing the fiber preform of the casing body 1 by using fibers on the outer circumference of the core mold 6 includes: arranging the first fibers in a crossed manner with the body section and the second fibers. As a specific form of manufacturing the fiber preform of the casing body 1, the first fibers and the second fibers can be used to weave a two-dimensional fabric or a three-dimensional fabric in a tubular shape on the outer circumference of the core mold 6 through a weaving process to form one or more layers of fiber preforms.

[0096] In the above embodiments, the arrangement directions of the first fibers and the second fibers are not unique, as long as the first fibers and the second fibers can form a crossed fabric structure with qualified strength. Moreover, for the first fibers and the second fibers with avoidance sections, as long as the avoidance sections of the first fibers and the avoidance sections of the second fibers bypass the second protruding portions 60a, 60b, and 60c. For example, outside the avoidance sections, that is, outside the positions corresponding to the accommodation holes, the first fibers 51 and 52 can be arranged along the axial direction of the core mold 6. For another example, outside the avoidance sections, that is, outside the positions corresponding to the accommodation holes, the second fibers 41, 42, and 43 can be arranged along the circumferential direction of the core mold 6.

[0097] In some embodiments, as Figure 3As shown, when manufacturing the first layer of fiber preform 10A on the core mold 6, outside the avoidance section, the first fibers 51 and 52 are arranged along the axial direction of the core mold 6 as warp yarns; outside the avoidance section, the second fibers 41, 42, and 43 are arranged along the circumferential direction of the core mold 6 as weft yarns. The first fibers 51 and 52 are arranged with the body sections intersecting the second fibers, and at least part of the length of the first fibers is greater than the length of the core mold 6. The parts extending beyond the two axial ends of the core mold 6 are used as reserved sections 51a, 52a, 51b, and 52b. The lengths of the reserved sections 51a and 52a and the lengths of the reserved sections 51b and 52b are determined according to the radial dimensions of the flanges 2 and 3 respectively. The reserved sections of the first fibers in the fiber preform 10A are taken as a group, and the reserved sections at both ends of the body section are respectively pulled to the constraint ends F1 and F2 and fixed. The second fibers are arranged between the second fibers 42 and 43 aligned with the two ends of the core mold 6.

[0098] After manufacturing the fiber preform 10A of the first layer of the casing body 1 on the core mold 6, more layers of fiber preforms of the casing body 1 can be successively manufactured outward along the radial direction of the core mold 6 according to the above method, such as the fiber preforms 10B and 10C of the casing body 1, until the number of layers required by the design is reached.

[0099] Step 1.4: Sleeve the first outer mold 7 outside the fiber preform of the casing body 1, as Figure 4 shown.

[0100] Step 1.5: Use fibers to manufacture the fiber preforms of the flanges 2 and 3 outside the axial end faces of the first outer mold 7.

[0101] As Figure 4 shown, in some embodiments, on the basis that the flanges 2 and 3 are provided with connection holes 21 and 31, in order to facilitate the fibers with avoidance sections to bypass the positions corresponding to the connection holes 21 and 31, the forming mold further includes a protruding part. The protruding part includes a first protruding part 70 arranged at the positions corresponding to the connection holes 21 and 31 on the first outer mold 7 and adapted to the shapes of the connection holes 21 and 31. The size of the first protruding part 70 is determined according to the size of the connection holes 21 and 31, and necessary process errors and curing deformation errors of the composite material are considered during design. In step 1.5, using fibers to manufacture the fiber preforms of the flanges 2 and 3 outside the axial end faces of the first outer mold 7 includes: making the avoidance sections of some fibers bypass the first protruding part 70. When manufacturing the fiber preforms of the flanges 2 and 3 in the above manner, necessary process errors and curing deformation errors of the composite material are considered.

[0102] In some embodiments, the fibers include a first fiber, a second fiber, and a third fiber. Among them, the first fiber includes a body section, and at least a part of the first fiber further includes reserved sections located at both ends of the body section. The body section and the reserved sections are respectively used to fabricate the fiber preform of the casing body 1 and the fiber preforms of the flanges 2 and 3. The body section of the first fiber, the reserved sections of the first fiber, the second fiber, and the third fiber may all include avoidance sections.

[0103] In step 1.5, fabricating the fiber preforms of the flanges 2 and 3 by using fibers outside the axial end face of the first outer mold 7 includes: arranging the first fiber with its reserved section intersecting the third fiber. As a specific form of fabricating the fiber preform of the casing body 1, the first fiber and the third fiber can be used to weave a tubular two-dimensional fabric or three-dimensional fabric on the circumferential outer side of the core mold 6 through a weaving process to form one or more layers of the fiber preform of the casing body 1.

[0104] In the above embodiments, the arrangement directions of the first fiber and the third fiber are not unique, as long as the first fiber and the third fiber can form an intersecting structure with qualified strength. And for the first fiber and the third fiber having avoidance sections, as long as the avoidance section of the first fiber and the avoidance section of the third fiber can bypass the first protrusion 70. For example, as Figure 6 and Figure 7 shown, outside the avoidance section, that is, outside the position corresponding to the connection hole, the reserved sections 53a, 54a, 55a, 56a, 57a, and 58a of the first fibers 51, 52 can be arranged radially along the first outer mold 7 as warp threads; for another example, as Figure 9 shown, outside the avoidance section, that is, outside the position corresponding to the connection hole, the third fibers 90, 91, 92, 93, 94, 95, 96, 97 can be arranged circumferentially along the core mold 6 as weft threads.

[0105] In some embodiments, as Figure 6 、 Figure 7 and Figure 9 shown, release the fixation of the reserved sections of the first fiber corresponding to the fiber preform of the outermost casing body 1 from the two constraint ends respectively, flip the reserved sections 53a, 54a, 55a, 56a, 57a, and 58a, and arrange them radially along the axial outer side end face of the first outer mold 7 outside the avoidance section as warp threads; outside the avoidance section, arrange the third fibers 90, 91, 92, 93, 94, 95, 96, 97 circumferentially along the core mold 6 as weft threads.

[0106] As Figure 5As shown, if the method of removing materials in the related art is used to obtain opening features such as connection holes, the reserved segments 53a, 54a, 55a, 56a, 57a, and 58a of the first fibers after flipping are radially distributed. When processing the connection hole 21, 53a, 54a, and 55a among them will be interrupted, and 56a may be damaged.

[0107] The present disclosure regarding the avoidance segment L1 of the first fiber bypassing the first protrusion 70 can adopt the following two methods.

[0108] In some embodiments, making the avoidance segments of some fibers bypass the first protrusion 70 includes: the avoidance segments L1 of two adjacent first fibers in the same layer bypass the first protrusion 70 side by side within the layer. For example, as Figure 6 shown, the first fibers 53a, 54a, 55a, and 56a in the same layer all include avoidance segments. Among them, the avoidance segment of the first fiber 53a fits against the side surface of the first protrusion 70, and the avoidance segments of the first fibers 53a, 54a, 55a, and 56a are arranged side by side to bypass the first protrusion 70, forming a laying method similar to concentric circles with different diameters.

[0109] In other embodiments, making the avoidance segments of some fibers bypass the first protrusion 70 includes: the avoidance segments of two adjacent first fibers in the same layer bypass the first protrusion 70 in a stacked manner along the thickness direction of the fiber preform of the flanges 2 and 3. For example, as Figure 7 shown, the first fibers 53b, 54b in one layer and the first fibers 55b, 56b in another layer all include avoidance segments. Among them, the avoidance segments of the first fibers 53b, 54b, 55b, and 56b all fit against the side surface of the first protrusion 70. Along the thickness direction of the fiber preform of the flanges 2 and 3, the first fiber 54b is stacked on the first fiber 53b, and the first fiber 56b is stacked on the first fiber 55b, forming a laying method similar to concentric circles with the same diameter. To better control the thickness of the fiber preform of the flange 3, corresponding yarn reduction R1 and R2 in the same direction as the setting direction of the body segments of the first fibers can be provided on the fiber preform of the casing body 1.

[0110] As Figure 8 shown, if the method of removing materials in the related art is used to obtain opening features such as connection holes, the third fibers 90, 91, 92, 93, 94, 95, 96, and 97 after flipping are concentrically distributed. When processing the connection hole 21, 93 and 94 among them will be interrupted, and 92 and 95 may be damaged.

[0111] The method of the present disclosure regarding the avoidance segment L3 of the third fiber bypassing the first protrusion 70 is as follows: As Figure 9As shown, the third fibers 90, 91, 92, 93, 94, 95, 96, 97 within the same layer are arranged outward in sequence along the radial direction of the first outer mold 7, wherein the third fibers 93, 94 have avoidance segments L3, and the avoidance segments L3 bypass the first convex portion 70 from both sides of the first convex portion 70 respectively.

[0112] Fix the first fibers and the third fibers arranged crosswise in a manner that does not affect the molding of the matrix material, such as traction fixation, stitching, applying a sizing agent, etc., to form the fiber preform 20C of the first layer flange 2 and the fiber preform 30C of the flange 3.

[0113] After manufacturing the fiber preform 20C of the first layer flange 2 and the fiber preform 30C of the flange 3 on the core mold 6, the fixing of the reserved segments of the first fibers corresponding to the fiber preforms of the other layers of the casing body 1 can be released in sequence, and the first fibers and the third fibers are arranged crosswise according to the above method to manufacture the fiber preforms of the flanges 2, 3 of each layer. For the first fibers in the outermost layer, the third fibers may not be provided.

[0114] According to the above manufacturing steps of the fiber preform, since the radius increases after the first fiber is flipped, the thickness of the fiber preform will gradually decrease. The thickness of the fiber preform can meet the design requirements by adjusting the specifications or distribution density of the first fibers and the third fibers, so as to form fiber preforms of the flanges 2, 3 with equal thickness or variable thickness.

[0115] In the manufacturing method of some embodiments, for a casing having a casing body 1 and flanges 2, 3, in step 2, manufacturing the composite material layer using the matrix material and the fiber preform includes steps 2.1 to 2.4.

[0116] Step 2.1: Provide a molding mold, including providing second outer molds 81, 82 of the mold body.

[0117] The second outer molds 81, 82 are used to form a closed cavity required for filling the matrix material with the core mold 6 and the first outer mold 7.

[0118] Step 2.2: Arrange the second outer molds 81, 82 on the outside of the fiber preforms of the flanges 2, 3 and form a closed cavity with the core mold 6 and the first outer mold 7, and the fiber preforms are located within the closed cavity, as Figure 10 shown.

[0119] The second outer molds 81, 82 can adopt carbide molds or flexible material molds.

[0120] Step 2.3: Fill the closed cavity with a matrix material, such as resin.

[0121] To prevent the matrix material from flowing into the surroundings of the first protrusion 70 and the second protrusions 60a, 60b, 60c when filling the matrix material, further sealing measures can be taken at the positions of the first protrusion 70 and the second protrusions 60a, 60b, 60c.

[0122] Step 2.4, Cure the matrix material and demold to form a composite material layer.

[0123] To facilitate demolding, a release agent can be applied to the surfaces of the core mold 6 and the first outer mold 7, especially the surfaces of the first protrusion 70 and the second protrusions 60a, 60b, 60c, before manufacturing the fiber preform.

[0124] In the casing of some embodiments not shown, the casing further includes a bushing provided on the inner wall of the hole to protect the hole.

[0125] Corresponding to the case where a bushing is provided on the inner wall of the hole of the casing, in the manufacturing method of some embodiments, the manufacturing method of the casing further includes: providing a bushing; detachably arranging the bushing on the outer wall of the first protrusion 70 and / or the outer walls of the second protrusions 60a, 60b, 60c. After the above-mentioned step 2 of manufacturing the composite material layer with the matrix material and the fiber preform, the bushing is demolded together with the composite material layer so that the casing includes a bushing integrally formed with the composite material layer.

[0126] In the casing of some embodiments not shown, the main body further includes a metal layer, and the metal layer of the main body and the composite material layer form a casing with a hybrid structure to further improve the mechanical properties of the casing.

[0127] Corresponding to the case where the main body of the casing includes a metal layer, in the manufacturing method of some embodiments, the manufacturing method of the casing further includes: providing a metal layer; detachably arranging the metal layer on the circumferential outer side of the core mold 6. After the above-mentioned step 2 of manufacturing the composite material layer with the matrix material and the fiber preform, the metal layer is demolded together with the composite material layer so that the casing includes a metal layer integrally formed with the composite material layer.

[0128] As Figures 2 to 10 shown, some embodiments of the present disclosure also provide a molding die for the aforementioned casing. Combined with the manufacturing method of the casing provided by the embodiments of the present disclosure, it can be used to manufacture the casing provided by some embodiments of the present disclosure and has the advantages of the casing of the embodiments of the present disclosure.

[0129] The molding die includes a die body and a protrusion. The protrusion is provided on the die body at a position corresponding to the hole and is adapted to the shape of the hole. When using this molding die to manufacture the casing of the embodiments of the present disclosure, the protrusion can occupy the position corresponding to the hole, and the avoidance section of the fiber can achieve the position corresponding to the hole by bypassing the protrusion.

[0130] In the molding die of some embodiments, the die body includes a core die 6, a first outer die 7, and second outer dies 81 and 82. The core die 6 is configured as a die for manufacturing the fiber preform of the casing body 1. The first outer die 7 is configured as a die for manufacturing the fiber preforms of the flanges 2 and 3. The second outer dies 81 and 82 are configured to form a closed cavity required for filling the matrix material with the core die 6 and the first outer die 7. The convex portion includes at least one of a first convex portion 70 and second convex portions 60a, 60b, and 60c. Among them, the first convex portion 70 is disposed at a position on the first outer die 7 corresponding to the connection holes 21 and 31 and is adapted to the shapes of the connection holes 21 and 31; the second convex portions 60a, 60b, and 60c are disposed at positions on the core die 6 corresponding to the receiving holes and are adapted to the shapes of the receiving holes.

[0131] The first convex portion 70 and the second convex portions 60a, 60b, and 60c can be respectively fixed to the core die 6 and the first outer die 7 by detachable connection means such as threaded connection. In order to facilitate demolding of the corresponding positions of the first convex portion 70 and the second convex portions 60a, 60b, and 60c, the first convex portion 70 and the second convex portions 60a, 60b, and 60c can be provided with a certain taper.

[0132] In the molding die of some embodiments not shown, a detachable bushing is provided on the outer wall of the first convex portion 70 and / or the second convex portions 60a, 60b, and 60c, and the bushing is configured to be integrally formed with the composite material layer.

[0133] In the molding die of some embodiments not shown, a detachable metal layer is provided on the circumferential outer side of the core die 6, and the metal layer is configured to be integrally formed with the composite material layer.

[0134] Regarding the functions of the bushing and the metal layer, and the manufacturing method of transferring the bushing and the metal layer from the molding die to the casing, reference can be made to the relevant descriptions above.

[0135] According to step 1.2 of the manufacturing method of the foregoing casing, in order to facilitate overall demolding of the molded casing, in the molding die of some embodiments, the core die 6 is a combined die. As Figure 2 shown, the core die 6 includes detachable core die components 6a, 6b, and 6c. The shapes and numbers of the core die components are determined according to the size and structural characteristics of the casing. Each core die component can be integrally processed or can be processed separately and then assembled into one body. The core die 6 can also adopt other assembly forms different from Figure 2 this.

[0136] According to step 1.2 of the manufacturing method of the foregoing casing, in order to facilitate overall demolding of the molded casing, in the molding die of some embodiments, the first outer die 7 is a combined die. As Figure 4As shown, the first outer mold 7 includes detachable first outer mold components 7a and 7b. The shapes and numbers of the first outer mold components are determined according to the size and structural characteristics of the casing. Each first outer mold component can be integrally processed or assembled into one after being processed separately. The first outer mold 7 can also be different from Figure 4 other assembly forms.

[0137] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present disclosure and are not intended to limit them; although the present disclosure has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that it is still possible to modify the specific implementation manners of the present disclosure or perform equivalent replacements on some technical features, and they should all be covered within the scope of the technical solutions claimed by the present disclosure.

Claims

1. A manufacturing method of a casing, the casing including a main body and holes provided on the main body, the main body including a composite material layer, the composite material layer including a matrix material and a fiber preform made of fibers, wherein, Some of the fibers include an avoidance section that bypasses the hole, and the manufacturing method is characterized in that the manufacturing method includes: Manufacturing the fiber preform using the fibers, including causing the avoidance section of some of the fibers to bypass the position corresponding to the hole; and Manufacturing a composite material layer using the matrix material and the fiber preform to form the casing; Wherein, the main body includes a casing body (1) and flanges (2, 3) located at both ends of the casing body (1), and manufacturing the fiber preform using the fibers includes: Providing the fibers; Providing a forming mold, including providing a core mold (6) for the main body of the mold and a first outer mold (7); Manufacturing the fiber preform of the casing body (1) on the circumferential outer side of the core mold (6) using the fibers; Sleeving the first outer mold (7) on the outer side of the fiber preform of the casing body (1); and Manufacturing the fiber preform of the flanges (2, 3) on the outer side of the axial end face of the first outer mold (7) using the fibers; Wherein, the hole includes connection holes (21, 31) provided on the flanges (2, 3), and providing the forming mold further includes providing a protruding portion, and the protruding portion includes a first protruding portion (70) provided at a position corresponding to the connection holes (21, 31) on the first outer mold (7) and adapted to the shape of the connection holes (21, 31), and manufacturing the fiber preform of the flanges (2, 3) on the outer side of the axial end face of the first outer mold (7) using the fibers includes: causing the avoidance section of some of the fibers to bypass the first protruding portion (70); The fibers include first fibers, and causing the avoidance section of some of the fibers to bypass the first protruding portion (70) includes: the avoidance sections of two adjacent first fibers in the same layer bypass the first protruding portion (70) side by side within the layer, the avoidance section of one of the first fibers in the same layer is attached to the side face of the first protruding portion (70), or, the avoidance sections of two adjacent first fibers in the same layer bypass the first protruding portion (70) stacked in the thickness direction of the fiber preform of the flanges (2, 3), and the avoidance section of each first fiber in the same layer is attached to the side face of the first protruding portion (70).

2. The manufacturing method of the casing according to claim 1, characterized in that The hole includes a receiving hole provided in the casing body (1), and providing the forming mold further includes providing a protruding portion, and the protruding portion includes second protruding portions (60a, 60b, 60c) provided at positions corresponding to the receiving hole on the core mold (6) and adapted to the shape of the receiving hole, and manufacturing the fiber preform of the casing body (1) on the circumferential outer side of the core mold (6) using the fibers includes: causing the avoidance section of some of the fibers to bypass the second protruding portions (60a, 60b, 60c).

3. The manufacturing method of the casing according to claim 2, characterized in that The fibers include second fibers and third fibers, the first fibers include a body section, and at least some of the first fibers further include reserved sections located at both ends of the body section. Manufacturing the fiber preform of the casing body (1) using the fiber on the outer circumferential side of the core mold (6) includes: arranging the first fiber to cross the second fiber at the body section; and / or Manufacturing the fiber preform of the flange (2, 3) using the fiber on the outer side of the axial end face of the first outer mold (7) includes: arranging the first fiber to cross the third fiber at the reserved section.

4. The manufacturing method of the casing according to claim 3, characterized in that, Outside the avoidance section, arranging the body section of the first fiber along the axial direction of the core mold (6); and / or arranging the reserved section of the first fiber along the radial direction of the first outer mold (7); and / or arranging the second fiber along the circumferential direction of the core mold (6); and / or arranging the third fiber along the circumferential direction of the first outer mold (7).

5. The manufacturing method of the casing according to claim 1, characterized in that, Providing a molding die further includes providing a second outer mold (81, 82) of the mold body; manufacturing a composite material layer using the matrix material and the fiber preform includes: arranging the second outer mold (81, 82) on the outer side of the fiber preform of the flange (2, 3) and forming a closed cavity with the core mold (6) and the first outer mold (7), and the fiber preform is located in the closed cavity; filling the matrix material into the closed cavity; and curing the matrix material and demolding to form the composite material layer.

6. The manufacturing method of the casing according to claim 2, characterized in that, Further includes: providing a bushing; disposably arranging the bushing on the outer wall of the first protrusion (70) and / or the outer wall of the second protrusions (60a, 60b, 60c); and after manufacturing the composite material layer using the matrix material and the fiber preform, demolding the bushing together with the composite material layer so that the casing includes the bushing integrally formed with the composite material layer.

7. The manufacturing method of the casing according to claim 1, characterized in that, Further includes: providing a metal layer; disposably arranging the metal layer on the outer circumferential side of the core mold (6); and after manufacturing the composite material layer using the matrix material and the fiber preform, demolding the metal layer together with the composite material layer so that the casing includes the metal layer integrally formed with the composite material layer.

8. A casing, characterized in that, Manufactured by the manufacturing method of the casing according to any one of claims 1 to 7.

9. An aero-engine, characterized in that, Includes the casing according to claim 8.

10. A forming die for a casing according to claim 8, characterized in that, Includes: A mold body for forming the composite material layer, the mold body includes a core mold (6), a first outer mold (7) and a second outer mold (81, 82), the core mold (6) is configured as a mold for manufacturing the fiber preform of the casing body (1), the first outer mold (7) is configured as a mold for manufacturing the fiber preform of the flange (2, 3), and the second outer mold (81, 82) is configured to form a closed cavity required for filling the matrix material with the core mold (6) and the first outer mold (7); and A raised portion, the raised portion is disposed on the mold body at a position corresponding to the hole and is adapted to the shape of the hole. The raised portion includes at least one of a first raised portion (70) and a second raised portion (60a, 60b, 60c). Wherein, the first raised portion (70) is disposed on the first outer mold (7) at a position corresponding to the connection holes (21, 31) and is adapted to the shape of the connection holes (21, 31), and the second raised portion (60a, 60b, 60c) is disposed on the core mold (6) at a position corresponding to the accommodation hole and is adapted to the shape of the accommodation hole.

11. The molding die according to claim 10, wherein the core mold (6) is a combined mold; and / or the first outer mold (7) is a combined mold.

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