A three-dimensional weaving method for weaving a composite material inlet casing preform

Abstract

The application discloses a weaving method for a three-dimensional weaving of a composite material inlet casing preform, and the method comprises the following steps: weaving an inner ring part, an outer ring part and a support plate to form a flat plate, bending the flat plate and connecting the first end and the tail end to make all the inner ring parts connect to form an annular inner ring, the outer ring parts form an annular outer ring, and the support plates are connected between the inner ring and the outer ring. The weaving method does not need to weave according to the original annular structure of the casing, so it is not necessary to redesign the weaving machine for the weaving operation of the casing preform, and the concentric ring multi-support plate structure fabric of the casing preform can be woven on the ordinary weaving machine such as a multi-arm weaving machine and a rapier loom in the prior art.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of composite material preform forming, and particularly relates to a three-dimensional weaving on-machine weaving method of a composite material inlet casing preform. BACKGROUND

[0002] The inlet casing frame structure of the aero-engine inlet casing is a load-bearing frame of the engine, such as the inlet casing frame structure disclosed in the patent application with the publication number CN111486004A, which comprises an inner ring, an outer ring and a plurality of connecting plates connecting the inner ring and the outer ring.

[0003] Generally, the inlet casing is prepared from metal materials or laminated composite materials. The metal material has low specific strength and low specific stiffness, which greatly limits the development goals of high thrust-to-weight ratio, low fuel consumption and low emission of the aero-engine. The laminated composite inlet casing has the disadvantages of non-uniform physical properties, poor impact resistance and low toughness, which limits the application of the inlet casing as a load-bearing structure, and the research on the composite inlet casing with an integrated structure is continued. The three-dimensional woven composite material has higher advantages in mechanical properties and design freedom, and the three-dimensional weaving technology can be applied to the field of composite material inlet casing preform forming to realize the three-dimensional weaving forming of the composite material inlet casing preform, meet the structural requirements of the aero-engine on the lightweight, integration and high strength of the inlet casing, and has a broad application prospect. However, since the casing preform is annular, it is difficult to weave by using the flat weaving machine commonly used in the prior art.

[0004] Therefore, a new technical solution is needed to solve the above problems. SUMMARY

[0005] The application provides a three-dimensional weaving on-machine weaving method of a composite material inlet casing preform, which can use the flat weaving method of the commonly used flat weaving machine to weave the annular casing preform.

[0006] Technical scheme: In order to achieve the above object, the application adopts the following technical scheme:

[0007] A three-dimensional weaving on-machine weaving method of a composite material inlet casing preform, comprising the following steps:

[0008] (1) providing the design parameters of the size and the number of connecting plates of the required composite material inlet casing preform, and dividing the overall structure of the composite material inlet casing preform into a plurality of regions according to the design parameters in the circumferential direction; each region comprises three groups of yarns, the first group of yarns are used to form part of the outer ring, the second group of yarns are used to form part of the inner ring, and the third group of yarns are used to form one or a plurality of connecting plates; each yarn is woven along the same straight line direction on the weaving machine after weaving;

[0009] (2) the weaving is cycled until the inner ring part and the outer ring part in all regions are woven to form a flat plate, at this time, the inner ring part and the outer ring part are in a flat plate form;

[0010] (3) the flat plate is bent and connected at the head and tail, so that all the inner ring parts are connected to form an annular inner ring, the outer ring parts form an annular outer ring, and the branch plates are connected between the inner ring and the outer ring.

[0011] Further, in step (2), the following sub-steps are included:

[0012] (2.1) threading;

[0013] (2.2) reeding;

[0014] (2.3) inputting a card pattern;

[0015] (2.4) weft insertion weaving;

[0016] (2.5) replacing the card pattern, and cycling (2.3) and (2.4) until the weaving of the fabric is completed.

[0017] Further, the threading method in step (2.1) is a forward threading method.

[0018] Further, the weft insertion path in step (2.4) is a straight one-way weft insertion, the weft insertion mode is rapier weft insertion, air jet weft insertion or water jet weft insertion, and the weft insertion quantity is single weft insertion or double weft insertion.

[0019] Further, the above steps are realized by using a multi-arm weaving machine or a rapier weaving machine.

[0020] Further, the basic structure form of the fabric is a three-dimensional orthogonal form.

[0021] Further, 12K carbon fibers are selected as the weaving raw materials.

[0022] Further, the inner ring part and the outer ring part in each region each include two strands, and when the flat plate is bent, the two strands of the inner ring part are symmetrically formed into two symmetrical parts of the inner ring annular two semicircles, and the two strands of the outer ring part are symmetrically formed into two symmetrical parts of the outer ring annular two semicircles.

[0023] Further, the required composite material inlet duct preform is divided into three equal parts, and each equal part is bent to form one-third of the outer ring, and the inner ring part corresponding to the outer ring part and the branch plate.

[0024] Further, during the weaving process, part of the warp yarns are always in a straightened state to provide tension for the forming of the preform.

[0025] Advantages: Compared with the prior art, the present application has the following advantages:

[0026] First, the warp yarns are woven according to the flat weaving idea, without the need to weave according to the original ring structure of the machine case, so there is no need to redesign the weaving machine for the weaving operation of the machine case preform, and the concentric circular ring multi-branch plate structure fabric of the machine case preform can be woven on the ordinary weaving machine such as the multi-arm weaving machine and the rapier loom in the prior art. Moreover, the continuity and integration of the fibers inside the fabric: the yarns penetrate the inner and outer rings and the branch plates in the middle of the rings, and the branch plates are connected between the inner and outer rings through the yarns, which enhances the integrity of the fabric. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 It is a three-dimensional view of the composite intake case preform before sewing in the present application.

[0028] Figure 2 It is a three-dimensional fabric yarn interweaving warp section view of the three-dimensional weaving structure of the composite intake case preform in the present application.

[0029] Figure 3 It is a first part of the warp section view of the on-machine weaving of the flattened yarns.

[0030] Figure 4 It is a first part of the warp section view of the on-machine weaving of the flattened yarns.

[0031] Figure 5 It is a second part of the warp section view of the on-machine weaving of the flattened yarns.

[0032] Figure 6 It is a second part of the warp section view of the on-machine weaving of the flattened yarns.

[0033] Figure 7 It is a I area pattern plate in the specific embodiment.

[0034] Figure 8 It is a II area pattern plate in the specific embodiment.

[0035] Figure 9 It is a III area pattern plate in the specific embodiment.

[0036] Figure 10 It is a XI area pattern plate in the specific embodiment. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical scheme and advantages of the present application clearer, the technical scheme of the present application will be further described in detail below in combination with the drawings and examples. It should be noted that the specific embodiments described here are only used to explain the present application, and are not used to limit the present application.

[0038] The embodiment discloses a weaving method for a composite air intake case preform three-dimensional machine weaving, and comprises the following steps.

[0039] (1) Please refer to Figure 1 and Figure 2 , provide the design parameters of the size and the number of support plates of the required composite air intake case preform. The composite air intake case preform comprises concentric outer rings and inner rings, and the outer rings and the inner rings are connected through support plates, and the outer rings, the inner rings and the support plates are integrally woven.

[0040] According to the design parameters, the overall structure of the composite air intake case preform is divided into several areas in the circumferential direction, in the embodiment, please refer to Figure 3 , Figure 5 , the design parameters are as follows: the diameter of the preform outer ring is 500 mm, the diameter of the inner ring is 300 mm, the number of support plates is 6, and the length of each support plate is 100 mm; at the same time, it has been designed in Figure 1 that the yarns numbered 1-14 are used to form the overall case structure. Then, after the fabric is flattened, it is divided into 11 areas according to the different thickness direction structures, and is named as I, II, III, …, XI respectively, and the weaving lengths of different areas are shown in Figures 3 to 6 , the length of I area is 104.62 mm, the length of II area is 100 mm, the length of III area is 57.08 mm, and so on, and the weaving length of XI area is 104.62 mm, different areas correspond to different pattern plates, the pattern plate of I area is shown in Figure 7 , the pattern plate of II area is shown in Figure 8 , the pattern plate of III area is shown in Figure 9 , and so on, and the pattern plate of XI area is shown in Figure 10 .

[0041] Each area comprises three groups of yarns, the first group of yarns is used to form part of the outer ring, the second group of yarns is used to form part of the inner ring, and the third group of yarns is used to form one or more support plates, and each group of yarns is extended along the same straight line direction on the loom after weaving. As shown in Figure 3 , the yarns numbered 3-5 and 10-12 are the first group of yarns, the yarns numbered 6-9 are the second group of yarns, and the yarns numbered 1, 2, 13 and 14 are the third group of yarns.

[0042] (2) As shown in Figure 3 , Figure 5 , weave until the inner ring part, the outer ring part and the support plate in all areas are woven to form a flat plate, at this time, the inner ring part and the outer ring part are in the form of a flat plate. During the weaving process, the warp yarns numbered 1, 2, 13, 14, 6, 7, 8 and 9 are always in the straightened state, providing tension for the formation of the preform.

[0043] The weaving on the loom comprises the following sub-steps:

[0044] (2.1) threading-in; since the number of warp yarn layers is large and the regularity is not significant, the fabric in the present example is woven by using the direct threading method.

[0045] (2.2) reeding;

[0046] (2.3) inputting the pattern plate;

[0047] (2.4) weft insertion and weaving;

[0048] (2.5) changing the pattern plate, and repeating the processes of (2.3) and (2.4) until the weaving of the fabric is completed.

[0049] (3) as shown in Figure 4 , Figure 6 , the flat plate is bent and connected at the ends, so that all the inner ring portions are connected to form an annular inner ring, the outer ring portions are connected to form an annular outer ring, and the support plates are connected between the inner ring and the outer ring.

[0050] Since the warp yarns are first woven according to the flat plate weaving idea in the above weaving process, and do not need to be woven according to the original annular structure of the loom cassette, it is not necessary to redesign the loom for the weaving operation of the loom cassette preform, and the concentric circular ring multi-support plate structure fabric of the loom cassette preform can be woven on the ordinary loom such as the multi-arm loom and the rapier loom in the prior art. Moreover, the continuity and integration of the fibers inside the fabric: the yarns penetrate the inner and outer rings of the fabric and the support plates between the inner and outer rings, and the support plates and the inner and outer rings are connected by the yarns, thereby enhancing the integrity of the fabric.

[0051] The above is only a preferred embodiment of the present application, and the protection scope of the present application is not limited to the above-mentioned embodiment. Any technical solution falling within the concept of the present application shall fall within the protection scope of the present application. It should be noted that, for ordinary skilled persons in the technical field, some improvements and refinements without departing from the principles of the present application shall be considered as falling within the protection scope of the present application.

Claims

1. A method of weaving a three-dimensional woven preform for a composite material inlet cowl, characterized in that, It comprises the following steps: (1) providing design parameters of the size of the required composite intake casing preform and the number of support plates, and dividing the overall structure of the composite intake casing preform into several regions according to the design parameters; each region includes three groups of yarns, the first group of yarns is used to form part of the outer ring, the second group of yarns is used to form part of the inner ring, and the third group of yarns is used to form one or several support plates; each strand of yarn extends along the same linear direction on the loom after weaving; (2) weaving in cycles until the inner ring part, the outer ring part, and the support plate in all regions are woven to form a flat plate, at which time the inner ring part and the outer ring part are in the form of a flat plate; (3) bending the flat plate and connecting the head and tail to make all the inner ring parts connect to form an annular inner ring, the outer ring parts form an annular outer ring, and the support plates are connected between the inner ring and the outer ring; the inner ring part and the outer ring part in each region each include two strands, and when bent, the two strands of the inner ring part symmetrically form symmetrical parts of the two semicircles of the annular inner ring, and similarly, the two strands of the outer ring part symmetrically form symmetrical parts of the two semicircles of the annular outer ring.

2. The method for three-dimensional woven fabrication of composite material intake casing preform according to claim 1, characterized in that, In step (2), the following sub-steps are included: (2.1) threading; (2.2) threading; (2.3) inputting the pattern plate; (2.4) weft insertion weaving; (2.5) changing the pattern plate, and repeating the processes of (2.3) and (2.4) until the weaving of the fabric is completed.

3. The method of claim 2, wherein the method is a three-dimensional machine weaving method for weaving a composite inlet cowl preform, characterized in that, The threading method in step (2.1) is the forward threading method.

4. The method for three-dimensional woven fabrication of composite material intake casing preform according to claim 2, characterized in that, The weft insertion path in step (2.4) is a straight one-way weft insertion, the weft insertion method is rapier weft insertion, air jet weft insertion, or water jet weft insertion, and the number of weft insertions is single weft insertion or double weft insertion.

5. The method of weaving a composite inlet cowl preform three-dimensional machine according to any one of claims 1 to 4, wherein, The above steps are realized by using a multi-arm loom or a rapier loom.

6. The method of claim 5, wherein the method is a three-dimensional machine weaving method for weaving a composite inlet cowl preform. The basic organizational structure of the fabric is a three-dimensional orthogonal form.

7. The method of claim 1, wherein the method is a three-dimensional machine weaving method for weaving a composite inlet cowl preform. 12K carbon fiber is selected as the weaving raw material.

8. The method for three-dimensional woven fabrication of composite material intake casing preform according to claim 4, characterized in that, The required composite intake casing preform is divided into three equal parts, and each equal part is bent to form one-third of the outer ring, as well as the inner ring part corresponding to the outer ring part and the support plate.

9. The method of weaving a composite inlet cowl preform three-dimensional machine according to claim 1 or 2, wherein, During the weaving process, part of the warp yarns are always in a straightened state to provide tension for the formation of the preform.

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