Method of manufacturing large thickness variable curvature complex composite fan blade

Abstract

The application discloses a manufacturing method of a large-thickness variable-curvature complex composite material fan blade, and comprises the following steps: for a tenon region of the fan blade, a hard mold is first laid, then an upper mold and a lower mold are combined, and tank curing is carried out; for a blade body region of the fan blade, a soft mold is first laid, then a bag is sealed, and tank curing is carried out. The two-sided hard mold mode is adopted for the tenon region, the one-sided hard mold process is adopted for the blade body region, the one-sided hard mold and the two-sided hard mold are simultaneously coupled in the manufacturing process of the composite material fan blade for the first time, the internal quality of the product can be effectively guaranteed to be optimal and defects are few, the thickness tolerance of the product meets the design requirement, the profile precision meets the aerodynamic requirement, and the manufacturing cost is effectively reduced.

Description

TECHNICAL FIELD

[0001] The application relates to a manufacturing method of a large-thickness variable-curvature complex composite material fan blade. BACKGROUND

[0002] Composite materials have the characteristics of light weight, high strength, designability, fatigue resistance and easy realization of structure / function integration, and have rapidly developed into one of the four structural materials of an aircraft. The autoclave process is the most common forming method for advanced composite materials, and has been widely used in the manufacturing process of main load-bearing and secondary load-bearing structures of an aircraft.

[0003] The composite material fan blade is to be formed by using a resin-based composite material autoclave, but the traditional vacuum bag single-sided hard mold pressurization method can realize direct loading of autoclave pressure to the surface of the prepreg stack, and the pressure distribution is usually uniform, but the surface of the formed part is prone to low profile accuracy due to the lack of a rigid mold. The double-sided hard mold pressurization method can well overcome the profile deviation problem, and therefore, in order to meet the high profile accuracy requirements of an aviation part, the double-sided hard mold pressurization method is widely concerned in the forming of complex wing surface structures. However, at the initial stage of forming, the rigid mold profile and the surface of the composite material are prone to form a non-tight fitting state, especially in the variable-thickness prepreg stack, which is more prone to occur, resulting in uncontrollable transmission behavior during the forming process, uneven pressure distribution and incomplete transmission of pressure at local positions of the composite material. Therefore, for the large-thickness variable-curvature complex composite material structure of the composite material fan blade, the traditional vacuum bag single-sided hard mold pressurization or double-sided hard mold pressurization cannot simultaneously meet the design aerodynamics, profile tolerance, product quality and other requirements. SUMMARY

[0004] The technical problem to be solved by the present application is to overcome the defects that the traditional vacuum bag single-sided hard mold pressurization or double-sided hard mold pressurization cannot simultaneously meet the design aerodynamics, profile tolerance, product quality and other requirements for the large-thickness variable-curvature complex composite material structure, and to provide a manufacturing method of a large-thickness variable-curvature complex composite material fan blade.

[0005] The present application solves the above technical problems by the following technical scheme:

[0006] A manufacturing method of a large-thickness variable-curvature complex composite material fan blade, characterized in that the manufacturing method comprises the following steps: for the tenon region of the fan blade, a hard mold is first laid and pasted, and then the upper mold and the lower mold are closed and cured in the autoclave; for the blade body region of the fan blade, a soft mold is first laid and pasted, and then the bag is sealed and cured in the autoclave.

[0007] Preferably, the manufacturing method further comprises: for the transition region of the fan blade, first laying the hard mold, then the upper mold and the lower mold are closed and cured in the tank.

[0008] Preferably, during the curing in the tank, the autoclave is first pressurized, then heated to raise the temperature of the fan blade to 170-180℃ and enter the holding stage.

[0009] Preferably, during the curing in the tank, the autoclave is first pressurized, then heated to raise the temperature of the fan blade to 170-180℃ and enter the holding stage.

[0010] Preferably, the autoclave is vacuumed to-0.074 MPa.

[0011] Preferably, the vacuum bag is connected to the atmosphere when the pressure of the autoclave reaches 0.14 MPa.

[0012] Preferably, after the vacuum bag is connected to the atmosphere when the pressure of the autoclave reaches 0.14 MPa, the autoclave is heated, and when the relative lagging thermocouple temperature of the fan blade reaches 90℃, the pressure is continuously increased to 0.6-0.7 MPa.

[0013] Preferably, the autoclave is pressurized to 0.61-0.63 MPa.

[0014] Preferably, the autoclave is heated at a heating rate of 2.5℃ / min.

[0015] Preferably, the holding stage lasts for 0.5 h.

[0016] Preferably, during the curing in the tank, internal pressure testing is performed: the pressure couple data in the autoclave and the pressure couple data in the fan blade are collected every 2 s.

[0017] On the basis of common sense in the art, the above-mentioned preferred conditions can be combined arbitrarily, i.e. to obtain each preferred example of the present application.

[0018] The positive progress effect of the present application is that the double-sided hard mold is used for the tenon region, the single-sided hard mold process is used for the blade body region, the single-sided hard mold and the double-sided hard mold are coupled in the manufacturing process of the composite fan blade for the first time, which can effectively ensure that the internal quality of the workpiece is optimal and the defects are few, the thickness tolerance of the workpiece meets the design requirements, the profile precision meets the aerodynamic requirements, and the manufacturing cost is effectively reduced. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 The figure is a schematic view of the large-thickness variable-curvature complex composite fan blade during manufacturing.

[0020] BRIEF DESCRIPTION OF DRAWINGS

[0021] Fan blade 1

[0022] Tenon region 11

[0023] Blade region 12

[0024] Transition region 13

[0025] Hard mold 2

[0026] Bilateral hard mold area 10

[0027] Unilateral hard mold area 20 DETAILED DESCRIPTION

[0028] The present application will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0029] The manufacturing method of the large-thickness variable-curvature complex composite material fan blade disclosed in the embodiments of the present application comprises the following steps: for the tenon region 11 of the fan blade 1, a hard mold 2 is first laid, and then the upper mold and the lower mold are combined and cured in a tank; for the blade region 12 of the fan blade 1, a soft mold is first laid, and then a bag is sealed and cured in a tank. Figure 1

[0030] The manufacturing method of the large-thickness variable-curvature complex composite material fan blade of the present embodiment obtains the layer-thickness-pressure correlation curve by analyzing the thickness direction pressure distribution, thickness gradient and porosity difference of the laminated plate with different thicknesses under the two process methods of unilateral hard mold and bilateral hard mold, thereby guiding the process curing system improvement of the large-thickness variable-curvature complex composite material fan blade. At the same time, the two process methods of unilateral hard mold and bilateral hard mold are first coupled in the manufacturing process of the composite material fan blade. The tenon region 11 adopts the bilateral hard mold mode, and the blade region 12 adopts the unilateral hard mold process. The two process methods of unilateral hard mold and bilateral hard mold are first coupled in the manufacturing process of the composite material fan blade, which can effectively ensure that the internal quality of the workpiece is optimal and the defects are few, the thickness tolerance of the workpiece meets the design requirements, the profile accuracy meets the aerodynamic requirements, and the manufacturing cost is effectively reduced.

[0031] ​The manufacturing method of the large-thickness variable-curvature complex composite fan blade further comprises: for the transition region 13 of the fan blade 1, first laying the hard mold 2, and then closing the upper mold and the lower mold and curing in the tank. For the fan blade 1, the double-sided hard mold area 10 and the single-sided hard mold area 20 are divided, and the tenon region 11 and the transition region 13 are located in the double-sided hard mold area 10, so that the hard mold 2 is first laid for the tenon region 11 and the transition region 13, and then the upper mold and the lower mold are closed and cured in the tank. The blade body region 12 is located in the single-sided hard mold area 20, so that the soft mold is first laid for the blade body region 12, and then the bag is sealed and cured in the tank.

[0032] In the process of curing in the tank, the autoclave is first pressurized, and then heated to raise the temperature of the fan blade 1 to 170-180°C and enter the holding stage. Preferably, the autoclave is heated at a temperature rising rate of 2.5°C / min. The holding stage lasts for 0.5h.

[0033] In the process of curing in the tank, the autoclave is first pressurized, and then heated to raise the temperature of the fan blade 1 to 170-180°C and enter the holding stage. Preferably, the autoclave is heated at a temperature rising rate of 2.5°C / min. The holding stage lasts for 0.5h.

[0034] In the process of pressurizing the autoclave, when the pressure of the autoclave reaches 0.14MPa, the vacuum bag is connected to the atmosphere.

[0035] After the vacuum bag is connected to the atmosphere when the pressure of the autoclave reaches 0.14MPa, the autoclave is heated, and when the relative lagging thermocouple temperature of the fan blade 1 reaches 90°C, the pressure is continued to be increased to 0.6-0.7MPa. Preferably, the autoclave is pressurized to 0.61-0.63MPa.

[0036] In the process of curing in the tank, the autoclave is first pressurized, and then heated to raise the temperature of the fan blade 1 to 170-180°C and enter the holding stage. Preferably, the autoclave is heated at a temperature rising rate of 2.5°C / min. The holding stage lasts for 0.5h.

[0037] In the process of curing in the tank: first increase the pressure of the autoclave to 0.63MPa (connect the vacuum bag to the atmosphere when the tank pressure reaches 0.14MPa), and then increase the temperature of the part to 180°C at a temperature rising rate of 2.5°C / min and hold for 0.5h.

[0038] In the process of curing in the tank, internal pressure testing is performed: every 2s, the pressure couple line data in the autoclave and the pressure couple line data in the fan blade 1 are collected.

[0039] Through process simulation: for the complex composite structure with large thickness and variable curvature and containing a large number of missing layers, the commonly used process software COMPRO is used for simulation calculation, the flow compaction process of the composite and the rigid mold contact is simulated, and the pressure state of different positions under the specific structure and specific layer is obtained.

[0040] Through internal pressure analysis: for thin plates, under pressure balance state, the double-sided hard mold form pressurization is the same as the single-sided hard mold / vacuum bag combination form pressurization, the internal pressure of the test piece is uniformly distributed, and is basically consistent with the tank pressure. For thick plates, there is a pressure distribution gradient along the thickness direction in the test piece.

[0041] Through metallographic method, the internal porosity state of different test pieces is analyzed, so as to obtain the internal porosity state of the theoretical thickness and the thickness deviation area. Based on the theoretical thickness, the thickness deviation of different porosity content test blocks is counted, so as to obtain the porosity content-thickness deviation relationship curve through metallographic method.

[0042] Therefore, different step pressurization systems are determined for different thicknesses of composite materials. For a 15mm laminated plate, the step pressurization system is vacuuming to-0.074MPa, then pressurizing, when the pressurization reaches 0.14MPa, the vacuum bag is connected to the atmosphere; then heating is started, when the fan blade 1 lags behind the thermocouple temperature by 90℃, the pressurization continues to 0.61MPa, and when the fan blade 1 lags behind the thermocouple temperature by 174℃, the heating enters the holding stage, and the holding stage time is 0.5h.

[0043] The manufacturing method of the large-thickness variable-curvature complex composite fan blade in the embodiment obtains the layering-thickness-pressure correlation curve by analyzing the thickness direction pressure distribution, thickness gradient and porosity difference of the laminated plate with different thicknesses under the single-sided hard mold and double-sided hard mold two process methods, thereby guiding the process and curing system improvement of the large-thickness variable-curvature complex composite fan blade, and for the first time, the single-sided hard mold and double-sided hard mold two process methods are simultaneously coupled in the manufacturing process of the composite fan blade. The double-sided hard mold is used for the tenon area 11 and the transition area 13, and the single-sided hard mold process is used for the blade area 12. For the first time, the single-sided hard mold and double-sided hard mold two process methods are simultaneously coupled in the manufacturing process of the composite fan blade, which can effectively ensure that the internal quality of the workpiece is optimal and the defects are few, the thickness tolerance of the workpiece meets the design requirements, the profile precision meets the aerodynamic requirements, and the manufacturing cost is effectively reduced.

[0044] Although the specific embodiments of the present application have been described above, it is understood by those skilled in the art that the present application is only illustrated by way of example, and the scope of protection of the present application is defined by the appended claims. Those skilled in the art can make various changes or modifications to the embodiments without departing from the principles and essence of the present application, and such changes and modifications fall within the scope of protection of the present application.

Claims

1. A method for manufacturing a fan blade made of a complex composite material with a large thickness and variable curvature, characterized in that, The manufacturing method of the composite material fan blade simultaneously couples both single-sided hard molding and double-sided hard molding processes. The manufacturing method includes the following steps: dividing the fan blade into a double-sided hard molding area and a single-sided hard molding area, with the tenon area located in the double-sided hard molding area and the blade body area located in the single-sided hard molding area; for the tenon area of ​​the fan blade, the double-sided hard molding process is adopted, first laying the hard mold, then closing the upper and lower molds and curing in a can; for the blade body area of ​​the fan blade, the single-sided hard molding process is adopted, first laying the soft mold, then sealing the bag and curing in a can. The manufacturing method further includes: the transition area is located within the double-sided hard mold area; for the transition area of ​​the fan blade, the hard mold is first laid on, and then the upper mold and the lower mold are joined together and put into a can for curing. During the curing process, the autoclave is first pressurized, and then heated to raise the temperature of the fan blades to 170-180°C and enter the heat preservation stage.

2. The method for manufacturing a thick, variable-curvature complex composite material fan blade as described in claim 1, characterized in that, During the curing process in the autoclave, a vacuum is drawn to -0.07 to 0.08 MPa before pressurizing the autoclave.

3. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 2, characterized in that, The autoclave was evacuated to -0.074 MPa.

4. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 1, characterized in that, When the pressure in the autoclave reaches 0.14 MPa, the vacuum bag is connected to the atmosphere.

5. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 4, characterized in that, After connecting the vacuum bag to the atmosphere when the pressure in the autoclave reaches 0.14 MPa, the autoclave is heated. When the temperature of the fan blade relative to the lag thermocouple reaches 90°C, the pressure is further increased to 0.6–0.7 MPa.

6. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 5, characterized in that, The autoclave is pressurized to 0.61–0.63 MPa.

7. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 1, characterized in that, The autoclave is heated at a heating rate of 2.5°C / min.

8. The method for manufacturing a large-thickness, variable-curvature complex composite material fan blade as described in claim 1, characterized in that, The heat preservation stage lasts for 0.5 hours.

9. The method for manufacturing a thick, variable curvature complex composite fan blade as described in claim 1, characterized in that, During the curing process in the autoclave, an internal pressure test is performed: pressure dipole data inside the autoclave and pressure dipole data inside the fan blades are collected every 2 seconds.

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