A method and apparatus for weaving a bladed disk fiber preform

Abstract

The application relates to a weaving method and equipment for a bladed disc fiber preform, and the weaving method comprises the following steps: connecting a fiber bundle on a fiber roll with a reel, arranging fiber felt on the left and right sides of the reel, winding the fiber bundle on the reel to form a ring-shaped fiber, after the diameter of the ring-shaped fiber reaches a target value, using a sewing fiber bundle to insert a radial fiber up and down between the ring-shaped fibers along the radial direction of the ring-shaped fiber, after one radial fiber is sewn, rotating the reel by a certain angle to sew along another radial direction, until a predetermined number of radial fibers are sewn, and a preform unit is obtained; repeating the above steps to prepare multiple preform units, stacking and paving the multiple preform units, and performing Z-direction puncturing on the multiple preform units by using a puncturing fiber, so that a bladed disc fiber preform is obtained. The weaving method has high efficiency, can realize mechanical weaving, and has a high fiber volume fraction of the preform, and can meet the requirements of a large-diameter high-speed rotating bladed disc.

Description

Technical Field

[0001] This invention relates to the field of high-performance bladed disk fiber preform weaving, and specifically to a method and equipment for weaving bladed disk fiber preforms. Background Technology

[0002] Existing impeller or turbine disk preforms are mainly formed by laying plain, twill, or satin weave fabrics of high-strength fibers such as carbon fiber and silicon carbide fiber, followed by Z-axis needle punching or piercing. Impellers made from this type of preform lack sufficient circumferential tensile strength during high-speed rotation, and are prone to circumferential fracture due to centrifugal force, failing to meet the requirements of high-speed rotation. This is because the existing preform weaving process does not adequately achieve the required circumferential tensile strength for the fibers, and the circumferential fiber winding density is insufficient, resulting in an excessively low volume fraction of the fiber preform in the finished impeller, thus failing to meet performance standards.

[0003] Therefore, there is a need for a method and equipment for weaving bladed disk fiber preforms that produces fiber preforms with high volume fraction and high circumferential fiber tensile strength, which can meet the requirements of high-speed rotating disk preforms such as large-diameter bladed disks and turbine disks. Summary of the Invention

[0004] In a first aspect, the present invention provides a method for weaving a bladed disk fiber preform, and the woven bladed disk fiber preform has a high volume fraction and high circumferential tensile strength, which can meet the requirements of high-speed rotating disk preforms such as large-diameter bladed disks and turbine disks.

[0005] The technical solution of the present invention is detailed below: a method for weaving a bladed disc fiber preform includes the following steps:

[0006] S1. To make a circumferential fiber cloth, the fiber bundles for weaving on the fiber roll are connected to the roll shaft. Fiber felt is fixed on the left and right sides of the roll shaft. When the roll shaft rotates, the fiber bundles for weaving are restricted between the fiber felt and wound around the roll shaft to form circumferential fibers. The circumferential fibers accumulate continuously as the roll shaft rotates to form a circumferential fiber cloth. The rotation plane of the roll shaft is a vertical plane.

[0007] S2. After the diameter of the circumferential fiber cloth reaches the target value, it is radially sewn using sewing fiber bundles. That is, sewing fiber bundles are used to interweave vertically between the circumferential fibers along the radial direction of the circumferential fiber cloth to form radial fibers. The two ends of the radial fibers are on the innermost and outermost circumferential fibers, respectively. After one radial fiber is sewn, the roller is rotated at a certain angle and then radial sewing is performed again along another radius until the predetermined number of radial fibers are sewn, thus obtaining the prefabricated unit.

[0008] S3. Repeat steps S1 and S2 to obtain multiple prefabricated units. Stack the multiple prefabricated units flat and use a puncture fiber bundle to puncture them in the Z direction to obtain the bladed disk fiber prefabricated body.

[0009] Beneficial effects: The bladed disk fiber preform weaving method of the present invention utilizes a rotating roller to achieve automatic winding of the fiber bundle. Vertical weaving increases the volume fraction of the circumferential fiber cloth; that is, for the same radius of circumferential fiber cloth, vertical weaving results in a higher volume fraction than horizontal weaving. See also Figure 1 , Figure 2 'a' is the cross-section of the fiber bundle used for weaving, and 'b' is the cross-section of the cotton thread used for textiles. It can be seen that, unlike the cotton thread used for textiles, the cross-section of the fiber bundle used for weaving is approximately rectangular. For example... Figure 3 As shown, when a fiber bundle is wound around a spool in a vertical plane, the diameter of the annular fiber cloth is equal to the sum of the shorter sides of the cross-section of the fiber bundle; and as... Figure 4 As shown, when the fiber bundle is wound into a disk shape in the horizontal plane, the diameter of the annular fiber cloth is equal to the sum of the long sides of the cross-section of the fiber bundle. It is easy to see that for annular fiber cloths with the same radius, Figure 3 The vertical weaving method can contain more fiber bundles, which increases the volume fraction of the circumferential fiber fabric.

[0010] In addition to helping the circumferential fiber cloth to take shape, the fiber felt on both sides of the roll can also maintain the shape of the prefabricated unit when weaving the radial fibers, making it less prone to loosening; at the same time, the woven prefabricated unit, combined with Z-axis needle punching or puncture technology, can improve Z-axis tensile strength and interlaminar shear force.

[0011] As described above, the fiber preform weaving method of the present invention is suitable for mechanized rapid weaving, and the woven preform has a high fiber volume fraction and features high circumferential tensile strength, radial tensile strength and Z-direction tensile strength, which can meet the requirements of high-speed rotating disk preforms such as large-diameter bladed disks and turbine disks.

[0012] Furthermore, in step S1, clamps are provided at both ends of the roll, and the fiber felt is placed between the two clamps. This design makes the fiber felt more stably positioned.

[0013] Furthermore, in step S2, the radial fibers include two fiber bundles that interweave between the circumferential fibers from two sides of the circumferential fiber cloth and hook together, thus binding the circumferential fibers into segments. This double-threaded interweaving structure of the radial fibers significantly increases the density of the prefabricated unit.

[0014] Furthermore, in step S2, both the fiber bundles and the circumferential fiber fabric used for sewing need to be sized before weaving. Sewing with fiber bundles can easily result in fuzz and broken fibers; therefore, sizing the fiber bundles and circumferential fiber fabric before sewing can improve these issues.

[0015] Furthermore, in step S2, the total rotation angle of the roller is 360 degrees, with each rotation being 360 / n degrees, where n is the predetermined number of radial fibers. Uniformly woven radial fibers increase the strength of the prefabricated unit.

[0016] Furthermore, the fiber used for puncture in step S3 is one of carbon fiber, silicon carbide fiber, glass fiber, basalt fiber, and polyimide high-performance fiber.

[0017] Furthermore, in step S3, the density of Z-axis punctures is 1–50 needles / cm. 2 .

[0018] Secondly, the present invention also provides an apparatus for the above-mentioned method of weaving fiber preforms for impellers, characterized in that it includes a fiber roll, a guide wheel assembly, a circumferential weaving mechanism and a radial sewing mechanism. The circumferential weaving mechanism includes a roller, fiber felts disposed on the left and right sides of the roller and columns supporting the roller. The fiber bundles for weaving on the fiber roll are transmitted to the circumferential weaving mechanism via the guide wheel assembly to be woven into a circumferential fiber cloth. The radial sewing mechanism uses sewing fiber bundles to radially sew the circumferential fiber cloth.

[0019] Furthermore, clamps are provided on both sides of the roll, and the fiber felt is placed between the two clamps. The clamps are perforated annular structures. By using perforated clamps, the radial sewing mechanism can weave radial fibers into the circumferential fiber cloth without removing the clamps.

[0020] Furthermore, the guide roller assembly includes at least two vertically staggered guide rollers. These guide rollers tighten the fiber bundle, increasing the density of the preform unit.

[0021] Furthermore, the radial sewing mechanism adopts a shuttle flat-seam structure.

[0022] The present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0023] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0024] Figure 1 This is a schematic cross-sectional view of the fiber bundle used for weaving according to the present invention;

[0025] Figure 2 A schematic diagram of the cross-section of cotton thread used in textiles;

[0026] Figure 3 This is a schematic diagram of the vertical winding structure of the fiber bundles used for weaving according to the present invention;

[0027] Figure 4 This is a schematic diagram of the horizontal winding structure of the fiber bundles for weaving according to the present invention;

[0028] Figure 5 This is a flowchart of the fiber preform weaving method for the impeller of the present invention;

[0029] Figure 6 This is a front view of the bladed disc fiber preform weaving device of the present invention;

[0030] Figure 7 This is a side view of the bladed disc fiber preform weaving device of the present invention;

[0031] Figure 8 This is a schematic diagram of radial fiber sewing in the bladed disk fiber preform weaving method of the present invention;

[0032] Figure 9 This is a schematic diagram of the structure of the preform unit in the bladed disk fiber preform weaving method of the present invention.

[0033] The above figures include the following reference numerals:

[0034] 1. Roller; 2. Clamping plate; 3. Fiber felt; 4. Circular fiber; 5. Radial fiber; 6. Circular fiber cloth; 71. Steel needle; 72. Shuttle; 8. Guide wheel assembly; 9. Fiber roll; 10. Column. Detailed Implementation

[0035] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings, but the present invention can be implemented in many different ways as defined and covered by the claims.

[0036] Example 1:

[0037] See Figures 5 to 9 This embodiment provides a method for weaving a bladed disc fiber preform:

[0038] S1. Connect the T700-12K fiber bundle for weaving on the fiber roll 9 to the roll 1 through the guide wheel group 8. Lay the fiber felt 3 containing carbon fiber on the inner surface of the clamping plate 2. Then install the two clamping plates 2 at the front and rear ends of the roll 1, leaving a gap of 4mm between the clamping plates 2. Then rotate the roll 1 to drive the fiber bundle for weaving to wind around the roll 1 to form circumferential fiber 4. The circumferential fiber 4 accumulates continuously to form circumferential fiber cloth 6.

[0039] S2. After the diameter of the circumferential fiber cloth 6 reaches 150mm, the roller 1 stops rotating. The T700-6K single fiber bundle used for sewing is then sized. The sized fiber bundle is threaded into the steel needle 71 and shuttle 72 of the radial sewing mechanism. Other components of the radial sewing mechanism are omitted from the diagram. The steel needle 71 sews up and down along the radial direction from the roller towards the outermost circumferential fiber, working in conjunction with the shuttle 72 to sew out the radial fiber 6. See [reference needed]. Figure 8 The radial fiber 5 is a double-stitched thread on the circumferential fiber fabric 6, which binds the circumferential fiber fabric 6 into segments. Each time the needle 71 is sewn, it moves upwards by 3mm, meaning that each sewing pass over multiple circumferential fibers. After the needle 71 sews from bottom to top to the outermost circumferential fiber, the roller 1 rotates 10°, and the needle 71 begins sewing from top to bottom to the roller. The roller then rotates 10° again, and this process is repeated until the roller 1 has rotated 360°. The radial sewing of the circumferential fiber fabric is then complete, resulting in a prefabricated unit. See [link / reference]. Figure 9 The circumferential fibers 4 of the prefabricated unit are closely adjacent, and multiple radial fibers 5 are sewn radially onto the prefabricated unit;

[0040] S3. Repeat steps S1 and S2, lay the prepared 50-layer prefabricated unit flat, and perform Z-axis puncture using a puncture process. The puncture fiber is a T700-6K single fiber bundle, and the puncture density is 25 needles / cm. 2 .

[0041] Thus, the preparation of a bladed disc fiber preform is complete. After densification, the density of the prepared bladed disc fiber preform reaches 2.2 g / cm³. 3 Tests were conducted according to GJB 6475-2008 "Standard Test Method for Tensile Properties of Continuous Fiber Reinforced Ceramic Matrix Composites at Room Temperature". The circumferential tensile strength exceeded 400 MPa, the radial tensile strength was 220 MPa, and the Z-direction tensile strength was 150 MPa. The fiber volume fraction of the bladed disk fiber preform can reach over 60%. Simulation analysis showed that the maximum circumferential stress was 290.54 MPa during high-speed rotation.

[0042] Simulation analysis of a high-speed rotating bladed disk revealed that the circumferential stress is greatest at high speeds. The bladed disk fiber preform manufactured using the fiber preform weaving method provided in this invention can provide both sufficiently high circumferential tensile force and sufficiently high radial tensile force.

[0043] See Figure 6This invention also provides a fiber preform weaving device for a bladed disc, including a fiber roll 9, a guide wheel assembly 8, a circumferential weaving mechanism, and a radial sewing mechanism. The circumferential weaving mechanism includes a roller 1, clamping plates 2 located at the front and rear ends of the roller 1, and a column 10 supporting the roller 1. The clamping plates 2 are hollowed-out annular structures with X-shaped brackets. The guide wheel assembly 8 includes four guide wheels, three of which are staggered vertically. The radial sewing mechanism adopts a shuttle flat sewing structure and includes a steel needle 71 and a shuttle 72. The remaining components of the radial sewing mechanism are omitted from the figure and are not shown.

[0044] Example 2:

[0045] The bladed disk fiber preform weaving method and equipment provided in Example 1 are used for weaving, the difference being that different fibers are used during weaving, different fiber widths are defined, and different frequencies are used for radial sewing.

[0046] The preparation steps of the bladed disc fiber preform provided in this embodiment are as follows:

[0047] First, make the circumferential fiber cloth by laying the carbon fiber felt 3 flat on the inner surface of the clamping plate, and then attach the two clamping plates 2 to the roller 1 with a 2mm gap between the clamping plates 2; use SiC fiber rolls, and connect the fibers to the roller 1 through the guide wheel 8. As the roller 1 rotates continuously, the diameter of the circumferential fiber cloth 6 reaches 85mm and then stops.

[0048] The SiC single fiber bundle is threaded into the radial sewing mechanism. The steel needle 71 and the shuttle 72 work together to perform radial sewing on the circumferential fiber cloth 6. Each time the steel needle 71 is sewn, it moves upward by 3 mm. After the steel needle 71 sewns to the outermost circumferential fiber 4, the roller 1 rotates by 3°. The steel needle 71 then starts sewing from top to bottom. After it reaches the roller 1, the roller 1 rotates by 3°. This process is repeated until the rollers have rotated 360°, forming a complete prefabricated unit.

[0049] Then, the 50-layer prefabricated unit is laid flat, and Z-axis puncture is performed using a puncture process. The Z-axis fiber bundles are SiC single fiber bundles, and the puncture density can be 25 needles / cm. 2 .

[0050] Thus, a highly efficient bladed disc fiber preform has been prepared. After densification, the prepared bladed disc fiber preform has a density of 2.2 g / cm³. 3 According to GJB 6475-2008 "Standard Test Method for Tensile Properties of Continuous Fiber Reinforced Ceramic Matrix Composites at Room Temperature", the circumferential tensile strength exceeds 500 MPa, the radial tensile strength is 300 MPa, the Z-direction tensile strength is 200 MPa, and the fiber volume fraction of the bladed disk fiber preform can reach more than 60%.

[0051] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A method for weaving a bladed disc fiber preform, characterized in that, Includes the following steps: S1. To make a circumferential fiber cloth, the fiber bundles for weaving on the fiber roll (9) are connected to the roller (1). Fiber felt (3) is fixed on the left and right sides of the roller (1). The rotation of the roller (1) causes the fiber bundles for weaving to wind around the roller (1) to form circumferential fibers (4). The winding area of ​​the fiber bundles for weaving is restricted between the fiber felts (3). The circumferential fibers (4) accumulate continuously as the roller (1) rotates to form a circumferential fiber cloth (6). The rotation plane of the roller (1) is a vertical plane. S2. After the diameter of the circumferential fiber cloth (6) reaches the target value, the roller (1) stops rotating and the circumferential fiber cloth (6) is radially sewn using sewing fiber bundles. That is, the sewing fiber bundles are used to interweave between the circumferential fibers (4) along the radial direction of the circumferential fiber cloth (6) to form radial fibers (5). The two ends of the radial fibers are on the innermost and outermost circumferential fibers (4) respectively. After one radial fiber (5) is sewn, the roller (1) rotates at a certain angle and then performs radial sewing along another radius until the predetermined number of radial fibers (5) are sewn, thus obtaining the prefabricated unit. S3. Repeat steps S1 and S2 to obtain multiple prefabricated units. Stack the multiple prefabricated units flat and puncture them in the Z-direction with a puncture fiber bundle to obtain the bladed disk fiber prefabricated body.

2. The method for weaving the bladed disc fiber preform according to claim 1, characterized in that, In step S1, the roller (1) is provided with clamps (2) on the left and right sides, and the fiber felt (3) is fixed on the two clamps (2) respectively.

3. The method for weaving the bladed disc fiber preform according to claim 1, characterized in that, The sewing fiber bundle in step S2 includes two single fiber bundles that pass through the circumferential fiber cloth (6) from both sides and interlock between the circumferential fibers (4) to bind the circumferential fiber cloth (6) in sections.

4. The method for weaving the bladed disc fiber preform according to claim 1, characterized in that, The sewing fiber bundles and circumferential fiber cloth (6) in step S2 need to be sized before sewing.

5. The method for weaving the bladed disc fiber preform according to claim 1, characterized in that, In step S2, the total rotation angle of the roller is 360 degrees, and each rotation is 360 / n degrees, where n is the predetermined number of radial fibers.

6. The method for weaving the bladed disc fiber preform according to claim 1, characterized in that, The fiber bundle used for puncture in step S3 is one of carbon fiber, silicon carbide fiber, glass fiber, basalt fiber, and polyimide high-performance fiber.

7. An apparatus for the method of weaving a bladed disc fiber preform according to any one of claims 1-6, characterized in that, The device includes a fiber roll (9), a guide wheel assembly (8), a circumferential weaving mechanism, and a radial sewing mechanism. The circumferential weaving mechanism includes a spool (1), fiber felts (3) located on the left and right sides of the spool (1), and a column (10) supporting the spool. The fiber bundles for weaving on the fiber roll (9) are transferred to the circumferential weaving mechanism via the guide wheel assembly to be woven into a circumferential fiber cloth (6). The radial sewing mechanism uses sewing fiber bundles to perform radial sewing on the circumferential fiber cloth (6).

8. The bladed disc fiber preform weaving equipment according to claim 7, characterized in that, The scroll (1) is provided with clamps (2) on the left and right sides, and the fiber felt (3) is located between the two clamps (2). The clamps (2) are hollow ring structures.

9. The bladed disc fiber preform weaving equipment according to claim 7, characterized in that, The guide wheel assembly (8) includes at least two guide wheels that are staggered vertically.

10. The bladed disc fiber preform weaving equipment according to claim 7, characterized in that, The radial sewing mechanism adopts a shuttle flat sewing structure, including a steel needle (71) and a shuttle (72).

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