A ceramic matrix composite blisk and improved method

Abstract

The application provides an improved method for a ceramic matrix composite integral blade disc, comprising the following steps: preparing a fiber preform according to the blade distribution density and the blade profile cross-sectional shape; obtaining a first integral blade disc according to the fiber preform; and setting a claw-shaped boss on the surface of the first integral blade disc to obtain a target integral blade disc; wherein the integral blade disc comprises a disc, N blades and a claw-shaped boss, and the disc and the claw-shaped boss are both made of a ceramic matrix composite. The ceramic matrix composite integral blade disc obtained from the fiber preform in the application can greatly improve the load capacity of the integral blade disc at the hub and the blade root part, and simultaneously reduce the difficulty and cycle of processing. Meanwhile, the claw-shaped boss set on the surface of the disc can effectively avoid the extrusion damage of the disc caused by the shaft deformation, and realize the effective force and torque transmission between the integral blade disc and the shaft.

Description

Technical Field

[0001] This invention relates to the field of integral bladed disk technology, and in particular to an integral bladed disk made of ceramic matrix composite material and an improved method thereof. Background Technology

[0002] The integral bladed disk is a new type of structural component designed to meet the needs of high-performance aero engines. It integrates the engine rotor blades and the disk into one piece, eliminating the need for tenons, mortises, and locking devices in traditional connections. This reduces structural weight and the number of parts, avoids airflow loss at the tenons, improves aerodynamic efficiency, and greatly simplifies the engine structure.

[0003] Existing research and fabrication experience with integral turbine bladed disks made of ceramic matrix composites is limited. The main method involves orthogonal plain weave of ceramic matrix composites, with the rotor center and blade root areas machined from the casing. This leads to issues such as insufficient strength in certain areas and presents significant processing challenges. Due to the increased hardness of ceramic matrix composites, machining tools experience significant wear during disk and blade profile fabrication, compromising the machining accuracy of complex surfaces and resulting in substantial material loss. Furthermore, the fabrication of orthotropic fiber preforms fails to consider the structural and stress characteristics of the integral bladed disk. Machining complex surfaces can also cause localized fiber damage. Since fibers are the primary load-bearing component of ceramic matrix composites, the final integral bladed disk lacks sufficient continuous load-bearing fibers in critical areas such as the rotor center and blade root, failing to leverage the performance advantages of ceramic matrix composites and limiting the overall strength of the bladed disk.

[0004] Meanwhile, regarding the force and torque transmission issues between the integral bladed disk and metal shaft of the ceramic matrix composite material, existing solutions for force and torque transmission between metal disks and metal shafts include interference fits and splines. However, if the spline structure in the metal disk solution is used, the manufacturing process is difficult and there are limitations on the disk's dimensions. If the interference fit solution in the metal disk solution is used, the metal shaft will deform more than the ceramic matrix composite disk under high-temperature conditions, which will compress the disk core and cause premature disk failure. Therefore, the commonly used fit methods for metal disks and shafts cannot be used in the connection scheme of the integral bladed disk and metal shaft of the ceramic matrix composite material.

[0005] Therefore, improving the integral bladed disk of ceramic matrix composite material has become an urgent problem to be solved. Summary of the Invention

[0006] The purpose of this invention is to provide a ceramic matrix composite integral bladed disk and an improved method thereon, which solves the above-mentioned technical problems.

[0007] To achieve the above objectives, the present invention provides an improved method for a ceramic matrix composite integral bladed disk, comprising:

[0008] Fiber preforms are prepared based on the leaf distribution density and the leaf cross-sectional shape.

[0009] A first integral bladed disk is obtained based on the fiber preform;

[0010] A claw-shaped boss is provided on the disk surface in the first integral bladed disk to obtain the target integral bladed disk;

[0011] The integral bladed disk includes a disk, N blades and claw-shaped bosses, and both the disk and the claw-shaped bosses are made of ceramic matrix composite material.

[0012] Optionally, based on the leaf distribution density and the leaf cross-sectional shape, a fiber preform is prepared, including:

[0013] Based on the blade distribution density, multiple blade polarity locally reinforced woven fabrics are obtained;

[0014] A fiber preform is prepared based on the plurality of blade polarity locally reinforced woven fabrics and the blade cross-sectional shape.

[0015] Optionally, obtain a polarity-reinforced woven fabric for each blade, including:

[0016] Establish a polar coordinate system on the horizontal plane where the roulette wheel is located;

[0017] Radial fiber bundles are arranged in the radial direction of the wheel;

[0018] By setting circumferential fiber bundles in the circumferential direction of the wheel, a polarity-reinforced woven fabric is obtained for each blade.

[0019] Optionally, radial fiber bundles are arranged in the radial direction of the wheel, including:

[0020] N first fiber bundles are uniformly fixed in the radial direction of the wheel;

[0021] Multiple second fiber bundles are uniformly arranged between any two first fiber bundles.

[0022] Optionally, by setting circumferential fiber bundles in the circumferential direction of the wheel, a polarity-reinforced woven fabric is obtained for each blade, including:

[0023] By using circumferential fiber bundles to insert radial fibers along the circumference of the wheel until the circumferential fiber weaving size reaches the outer diameter of the wheel, a polarity-reinforced woven fabric for each blade is obtained.

[0024] Optionally, the ratio of reinforcing fiber monofilament content in the first fiber bundle and the second fiber bundle is 2:1.

[0025] Optionally, based on the plurality of blade polarity-reinforced woven fabrics and the blade cross-sectional shape, a fiber preform is prepared, including:

[0026] Determine the quantity of locally reinforcing woven fabric for multiple blade polarities;

[0027] Based on the quantity and the shape of the blade cross section, determine the circumferential deflection angle of the polar local reinforcement woven fabric for each blade;

[0028] According to the circumferential deflection angle, the polar local reinforcement woven fabric of each blade is laid out, and all the polar local reinforcement woven fabrics of the blades are sewn together to obtain a fiber preform.

[0029] Optionally, the claw-shaped boss includes: a fan-shaped transition section and an annular boss section composed of multiple arc-shaped boss segments;

[0030] The arc-shaped protrusions are evenly distributed along the circumference of the wheel, and the width of the arc-shaped protrusions increases with the radius of the wheel; the annular protrusions are coaxial with the wheel.

[0031] Optionally, the target integral bladed disk further includes: a circular metal clip prepared according to the claw-shaped boss, wherein the circular metal clip is embedded in the claw-shaped boss.

[0032] The present invention also provides an integral bladed disk, comprising: the integral bladed disk including a disk, N blades and claw-shaped bosses, wherein the disk and the claw-shaped bosses are both made of ceramic matrix composite material; wherein the claw-shaped bosses are provided on the surface of the disk.

[0033] The technical effects and advantages of this invention are as follows:

[0034] This invention provides an improved method for an integral bladed disk made of ceramic matrix composite material, comprising: preparing a fiber preform according to the blade distribution density and the blade airfoil cross-sectional shape; obtaining a first integral bladed disk according to the fiber preform; and setting a claw-shaped boss on the disk surface in the first integral bladed disk to obtain a target integral bladed disk; wherein the integral bladed disk includes a disk, N blades and claw-shaped bosses, and both the disk and the claw-shaped bosses are made of ceramic matrix composite material.

[0035] The integral ceramic matrix composite bladed disk obtained by the fiber preform according to the present invention can significantly improve the load-bearing capacity of the integral bladed disk at the wheel center and blade root, while reducing the difficulty and cycle of processing. At the same time, due to the claw-shaped bosses provided on the surface of the disk, the crushing and damage to the disk after shaft deformation is effectively avoided, and effective force and torque transmission between the integral bladed disk and the shaft is realized.

[0036] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0037] Figure 1 A flowchart illustrating the improved method for integral bladed disks made of ceramic matrix composites;

[0038] Figure 2 To consider the polarized woven fiber pattern for uniform blade distribution;

[0039] Figure 3 Diagram showing the required quantity of polarized woven fabric to reinforce the blades of the rotary disc;

[0040] Figure 4 This is a diagram showing the axial distribution of the airfoil cross-sectional shape.

[0041] Figure 5 A fiber-woven fabric layup diagram considering the blade angle;

[0042] Figure 6 This is a diagram of a claw-shaped boss structure.

[0043] Figure 7 This is a diagram of the claw-shaped boss structure on the surface of the wheel;

[0044] Figure 8 This is a diagram of a circular metal clip. Detailed Implementation

[0045] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Furthermore, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0046] It should be noted that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed herein. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention.

[0047] To address the shortcomings of existing technologies, this invention provides an improved method for producing a ceramic matrix composite integral bladed disk, comprising: preparing a fiber preform according to the blade distribution density and the blade airfoil cross-sectional shape; obtaining a first integral bladed disk based on the fiber preform; and setting a claw-shaped boss on the disk surface in the first integral bladed disk to obtain a target integral bladed disk; wherein the integral bladed disk includes a disk, N blades, and claw-shaped bosses, and both the disk and the claw-shaped bosses are made of ceramic matrix composite material.

[0048] The integral ceramic matrix composite bladed disk obtained by the fiber preform according to the present invention can significantly improve the load-bearing capacity of the integral bladed disk at the wheel center and blade root, while reducing the difficulty and cycle of processing. At the same time, due to the claw-shaped bosses provided on the surface of the disk, the crushing and damage to the disk after shaft deformation is effectively avoided, and effective force and torque transmission between the integral bladed disk and the shaft is realized.

[0049] To better understand this solution, the following will be combined with... Figure 1 This paper details the improvement methods for integral bladed disks made of ceramic matrix composites. The improvements mainly consist of two parts: the fiber preform and the disk's force and torque transmission.

[0050] Step 1: Prepare fiber preforms based on the leaf distribution density and the leaf cross-sectional shape.

[0051] Specifically, this includes: 1. A weaving scheme for polarized local reinforcement of woven fiber cloth that considers uniform distribution of blades.

[0052] Since the overall bladed disk structure is a disk-shaped structure, and the disk and blades are an integral structure, the polar coordinate system is selected as the reference coordinate system for the fiber preform. The fiber bundle weaving direction is both radial and circumferential.

[0053] Determine the inner diameter r and outer diameter R of the overall bladed disk, as well as the number of blades (N).

[0054] To ensure fiber continuity at both the wheel center and the connection between the wheel and the blades, N sets of blade fiber bundles 1 are first uniformly fixed along the circumference in the radial direction of the wheel, and m sets of fiber bundles 2 are evenly distributed between the blade fiber bundles. The ratio of the reinforcing fiber monofilament content in blade fiber bundle 1 to that in fiber bundle 2 is 2:1.

[0055] After the radial fiber bundle is fixed, the circumferential fiber bundle 3 is inserted into the radial fiber weaving along the circumference of the wheel until the circumferential fiber weaving size reaches the outer diameter of the wheel, thus obtaining the blade polarity locally reinforced woven fabric, as shown below. Figure 2 As shown.

[0056] 2. Fiber woven fabric layup scheme considering blade angle

[0057] The integral bladed disk has a certain thickness along the axial direction, therefore, the blade polarity reinforcement woven fabric obtained in the above steps needs to be introduced into the axial fiber bundles in the thickness direction for sewing. Simultaneously, considering the certain inclination angle of the leading and trailing edges of the blades, it is necessary to first determine the number L layers of blade polarity reinforcement woven fabric required for the disk, such as... Figure 3 As shown; then, based on the blade cross-sectional shape, the circumferential deflection angle θ of each layer of the blade polar local reinforcement woven fabric is determined. The deflection angle θ is determined based on ensuring that the radial fibers reinforcing the blade in the blade polar local reinforcement woven fabric have the same deflection angle in the thickness direction as the blade angle, such as... Figure 4 As shown; finally, after laying out the blade polarity reinforcement woven fabric with reference to the deflection angle, all the blade polarity reinforcement woven fabrics are sewn together to obtain the fiber preform (i.e., the integral fiber preform), as shown. Figure 5 As shown.

[0058] Step 2: Obtain the first integral bladed disk based on the fiber preform.

[0059] Step 3: Set a claw-shaped boss on the disk surface in the first integral bladed disk to obtain the target integral bladed disk.

[0060] The claw-shaped boss structure mainly consists of two parts: a fan-shaped transition section 1 and an annular boss section 2, such as... Figure 6 As shown in the diagram, the fan-shaped transition section comprises 12 arc-shaped boss segments, evenly distributed circumferentially, with the width of each segment increasing as the wheel radius increases. The annular boss segment is located near the wheel center and connects with the 12 arc-shaped boss segments to form a complete claw-shaped boss structure.

[0061] Adding claw-shaped bosses to the surface of the wheel can effectively transfer the deformation differences between the metal shaft and the ceramic matrix composite wheel. The claw-shaped boss structure on the surface of the ceramic matrix composite wheel, such as... Figure 7 As shown. The inner diameter r1 of the claw-shaped boss is equal to the inner diameter r of the integral bladed disk. Both the boss and the disk are made of ceramic matrix composite material.

[0062] Simultaneously, circular metal clips are prepared based on the claw-shaped boss structure, such as... Figure 8 As shown, a circular metal clip incorporates a claw-shaped boss structure, where the inner diameter r2 of the embedded boss is smaller than the inner diameter r of the overall bladed disk. The circular metal clip and the metal shaft are interference-fitted, and the claw-shaped boss engages with the ceramic matrix composite disk to transmit force and torque. Differences in material deformation are mitigated by the curved surface of the fan-shaped transition section within the claw-shaped boss. Due to the high hardness of the ceramic matrix composite material and the significant difficulty in removing the material, the circular metal clip can also serve as a material removal component for dynamic balancing of the disk.

[0063] This invention solves the problems of fiber continuity and fiber volume fraction at the connection between the blade and the disk in the integral bladed disk structure of ceramic matrix composite material, ensuring that the high-stress dangerous area has sufficient load-bearing capacity. At the same time, it addresses the problem of force and torsion transmission between the integral bladed disk and the metal shaft of ceramic matrix composite material, ensuring that the integral bladed disk and the metal shaft will not fail prematurely due to large deformation differences under high temperature conditions, and provides an adjustable structure for the dynamic balance adjustment of the ceramic matrix composite material disk structure.

[0064] The present invention also provides an integral bladed disk, comprising: the integral bladed disk including a disk, N blades and claw-shaped bosses, wherein the disk and the claw-shaped bosses are both made of ceramic matrix composite material; wherein the claw-shaped bosses are provided on the surface of the disk.

[0065] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An improved method for an integral bladed disk made of ceramic matrix composite material, characterized in that, include: Fiber preforms are prepared based on the leaf distribution density and the leaf cross-sectional shape. A first integral bladed disk is obtained based on the fiber preform; A claw-shaped boss is provided on the disk surface in the first integral bladed disk to obtain the target integral bladed disk; The integral bladed disk includes a disk, N blades and claw-shaped bosses, and both the disk and the claw-shaped bosses are made of ceramic matrix composite material; The claw-shaped boss includes: a fan-shaped transition section and an annular boss section composed of multiple arc-shaped boss segments; The arc-shaped boss segments are evenly distributed along the circumference of the wheel, and the width of the arc-shaped boss segments increases with the increase of the wheel radius; the annular boss segments are coaxial with the wheel. The target integral bladed disk further includes: a circular metal clip prepared according to the claw-shaped boss, wherein the circular metal clip is embedded in the claw-shaped boss.

2. The method according to claim 1, characterized in that, Based on the leaf distribution density and the leaf cross-sectional shape, a fiber preform is prepared, including: Based on the blade distribution density, multiple blade polarity locally reinforced woven fabrics are obtained; A fiber preform is prepared based on the plurality of blade polarity locally reinforced woven fabrics and the blade cross-sectional shape.

3. The method according to claim 2, characterized in that, Obtaining a polarity-reinforced woven fabric for each blade includes: Establish a polar coordinate system on the horizontal plane where the roulette wheel is located; Radial fiber bundles are arranged in the radial direction of the wheel; By setting circumferential fiber bundles in the circumferential direction of the wheel, a polarity-reinforced woven fabric is obtained for each blade.

4. The method according to claim 3, characterized in that, Radial fiber bundles are arranged in the radial direction of the wheel, including: N first fiber bundles are uniformly fixed in the radial direction of the wheel; Multiple second fiber bundles are uniformly arranged between any two first fiber bundles.

5. The method according to claim 3, characterized in that, By setting circumferential fiber bundles in the circumferential direction of the wheel, a polarity-reinforced woven fabric is obtained for each blade, including: By using circumferential fiber bundles to insert radial fibers along the circumference of the wheel until the circumferential fiber weaving size reaches the outer diameter of the wheel, a polarity-reinforced woven fabric for each blade is obtained.

6. The method according to claim 4, characterized in that, The ratio of reinforcing fiber monofilament content in the first fiber bundle and the second fiber bundle is 2:

1.

7. The method according to claim 2, characterized in that, Based on the plurality of blade polarity-reinforced woven fabrics and the blade cross-sectional shape, a fiber preform is prepared, comprising: Determine the quantity of locally reinforcing woven fabric for multiple blade polarities; Based on the quantity and the shape of the blade cross section, determine the circumferential deflection angle of the polar local reinforcement woven fabric for each blade; According to the circumferential deflection angle, the polar local reinforcement woven fabric of each blade is laid out, and all the polar local reinforcement woven fabrics of the blades are sewn together to obtain a fiber preform.

8. The integral bladed disk prepared according to any one of claims 1-7, characterized in that, include: The integral bladed disk includes a disk, N blades and claw-shaped bosses, and both the disk and the claw-shaped bosses are made of ceramic matrix composite material; wherein, the claw-shaped bosses are provided on the surface of the disk.

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