Preparation method of composite material blade

Abstract

The composite material blade preparation method is used for preparing a blade from a composite material, the blade comprises a blade body, an upper edge plate and a lower edge plate, and the method comprises the following steps that yarn bundles are used for weaving an upper edge plate prefabricated body or a lower edge plate prefabricated body; one part of the yarn bundles is led out, and the led-out part of the yarn bundles continues to be woven into a blade body prefabricated body; after a blade prefabricated body formed by the upper margin plate prefabricated body, the lower margin plate prefabricated body and the blade body prefabricated body is obtained, a mold is used for wrapping the blade prefabricated body; and heating the blade preform, injecting resin into the cavity of the mold, and curing and demolding to form the blade. The blade prepared by the method has better stability and safety.

Description

Technical Field

[0001] The present invention relates to the field of aeroengines, and in particular to the field of blade preparation. Background Art

[0002] In order to further improve the efficiency of turbofan engines and reduce fuel consumption, increasing the bypass ratio of the engine is an effective technical means. As the bypass increases, the size of the fan blades, casing and fan bypass outlet guide vanes (OGV) also increases, which will lead to an increase in the proportion of the fan section weight to the total engine weight or an increase in the weight of the entire engine. Therefore, in order to meet the engine low fuel consumption design requirements and improve the market competitiveness of large passenger engines, engine weight reduction has become one of the main goals of major engine manufacturers.

[0003] Due to the advantages of composite materials in specific strength and specific stiffness, currently, using composite materials to replace traditional metal materials is an effective method and means for major engine manufacturers to improve engine thrust-to-weight ratio and reduce engine weight.

[0004] Currently, one-dimensional or two-dimensional fabrics or prepregs are often used to manufacture stator blades. However, the connection strength between the blade body and the upper and lower edge plates is low. Under long-term service conditions, cracking is very likely to occur under the stress of vibration fatigue. Summary of the invention

[0005] An object of the present invention is to provide a method for preparing a blade, wherein the prepared blade has better stability and safety.

[0006] A composite material blade preparation method for achieving the above-mentioned purpose is used to prepare blades using composite materials, and the blade includes a blade body, an upper edge plate and a lower edge plate, and the method includes the following steps: using yarn bundles to weave an upper edge plate preform or a lower edge plate preform; drawing out a part of the yarn bundles, so that the partially drawn yarn bundles continue to weave the blade body preform; after obtaining a blade preform formed by the upper edge plate preform, the lower edge plate preform and the blade body preform, using a mold to wrap the blade preform; heating the blade preform, injecting resin into the mold cavity of the mold, and forming a blade after curing and demolding.

[0007] In one or more embodiments, the lower edge plate preform is weaved using the lower edge plate yarn bundle, and the upper edge plate preform is weaved using the upper edge plate yarn bundle, so that a portion of the lower edge plate yarn bundle and a portion of the upper edge plate yarn bundle are combined to weave the blade body preform.

[0008] In one or more embodiments, a portion of the lower edge plate yarn bundle is woven to form a first blade airfoil preform section, a portion of the upper edge plate yarn bundle is woven to form a second blade airfoil preform section, and the first blade airfoil preform section and the second blade airfoil preform section are combined and woven into the blade airfoil preform.

[0009] In one or more embodiments, the yarn bundle arrangement of the blade body preform includes one or more of the following: sequential stacking, interleaved insertion, and alternating insertion.

[0010] In one or more embodiments, the yarn bundle is used to weave a lower edge plate preform or an upper edge plate preform, a portion of the yarn bundle is drawn out to continue weaving a blade body preform, and the drawn out portion of the yarn bundle is continued to weave an upper edge plate preform or a lower edge plate preform.

[0011] In one or more embodiments, the yarn bundles are used to weave a lower edge plate preform or an upper edge plate preform, a portion of the yarn bundles are drawn out to continue weaving a blade preform, and a portion of the yarn bundles of the blade preform are drawn out to continue weaving an upper edge plate preform or a lower edge plate preform.

[0012] In one or more embodiments, the yarn bundle is used to start weaving from both ends of the upper edge plate preform or the lower edge plate preform along the length direction to obtain at least a portion of the upper edge plate preform or at least a portion of the lower edge plate preform; the surface yarn bundle for preparing the upper edge plate preform or the lower edge plate preform is lifted up and led out, and combined with other yarn bundles to form a blade body yarn bundle to weave the blade body preform; the yarn bundle for preparing the surface layer of the blade body preform is lifted up and led out, and combined with other yarn bundles to weave the lower edge plate preform or the upper edge plate preform.

[0013] In one or more embodiments, a portion of the yarn bundle that is drawn out forms an angle with the yarn bundle that is not drawn out.

[0014] In one or more embodiments, the angle is ≥30°.

[0015] In one or more embodiments, the yarn bundle is one or more of carbon fiber, glass fiber, Kevlar fiber, polyimide fiber, and SiC fiber.

[0016] In one or more embodiments, the yarn bundle includes warp yarns and weft yarns, and the drawn yarn bundle is the warp yarn.

[0017] In one or more embodiments, the yarn bundles used to prepare the upper edge plate preform and the lower edge plate preform are at least two layers, and the yarn bundles drawn out are at least one layer.

[0018] In one or more embodiments, the number of yarn bundles, the number of layers, and the weaving structure are selected and adjusted according to the thickness of the blade body and the edge plate and the inter-layer strength of the preform.

[0019] In one or more embodiments, at the connection between the edge plate preform and the blade body preform, the number of warp and weft interlacing points on the upper surface of the lead-out yarn bundle is greater than the number of warp and weft interlacing points on the lower surface of the lead-out yarn bundle.

[0020] In one or more embodiments, at the connection between the edge plate preform and the blade body preform, the K bundles of weft yarns of the lead-out yarn bundles close to the upper surface and the upper surface are greater than the K bundles of weft yarns close to the lower surface and the lower surface.

[0021] In one or more embodiments, at the connection between the edge plate preform and the blade body preform, the diameter of the weft yarn of the lead-out yarn bundle close to the upper surface and the upper surface is greater than the diameter of the weft yarn close to the lower surface and the lower surface.

[0022] In one or more embodiments, the weaving method for preparing the blade preform includes one or more of weaving, braiding, knitting or stitching.

[0023] The above-mentioned composite material blade preparation method can use the lead-out yarn bundle to directly weave the blade body preform during the preparation process of the blade preform, so that the yarn bundle exists at the connection between the blade body and the edge plate. In this way, there is not only matrix material but also fiber connection inside the blade body and between the blade body and the edge plate. The interlayer strength inside the blade body and between the blade body and the edge plate can be improved, the probability of failure occurring at the interface between each layer is reduced, and the safety and stability of the blade structure are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments, in which:

[0025] Figure 1 It is a schematic diagram of the structure of the stator blade;

[0026] Figure 2 is a schematic diagram of the process of preparing the upper edge plate preform;

[0027] Figure 3 It is a schematic diagram of the process of preparing a blade body preform;

[0028] Figure 4 is a schematic diagram of the process of preparing the upper edge plate preform;

[0029] Figure 5 Schematic diagram of the process of preparing a blade body preform by using an upper edge plate yarn bundle and a lower edge plate yarn bundle together;

[0030] Figure 6 Schematic diagram of outer and inner yarn bundles at the connection between the edge plate preform and the blade body preform;

[0031] Figure 7 It is a flow chart of the method for preparing composite blades. DETAILED DESCRIPTION

[0032] The present invention is further described below in conjunction with specific embodiments and drawings. More details are elaborated in the following description to facilitate a full understanding of the present invention. However, the present invention can obviously be implemented in a variety of other ways different from the description herein. Those skilled in the art can make similar generalizations and deductions based on actual application situations without violating the connotation of the present invention. Therefore, the protection scope of the present invention should not be limited by the content of this specific embodiment.

[0033] It should be noted that these and other subsequent drawings are only examples and are not drawn to scale, and should not be used to limit the actual scope of protection required by the present invention.

[0034] Figure 1 It is a stator blade structure, including a blade body 11, an upper edge plate 12 and a lower edge plate 13, wherein the upper edge plate 12 and the lower edge plate 13 are collectively referred to as edge plates. When preparing a stator blade, it is necessary to prepare a blade body preform 5, an upper edge plate preform 1 and a lower edge plate preform 9, and the combination of the blade body preform 5, the upper edge plate preform 1 and the lower edge plate preform 9 is a blade preform.

[0035] The composite blade preparation method disclosed in the present invention is used to prepare blades using composite materials, and includes the following steps: using a yarn bundle 100 to weave an upper edge plate preform or a lower edge plate preform; drawing out a portion of the yarn bundle 100 so that the partially drawn yarn bundle continues to weave a blade body preform; after obtaining a blade preform formed by the upper edge plate preform, the lower edge plate preform and the blade body preform, using a mold to wrap the blade preform; heating the blade preform, injecting resin into the mold cavity of the mold, and forming a blade after curing and demolding.

[0036] When preparing the blade body preform and the edge plate preform, the part of the yarn bundles drawn out are used for weaving together, so that the yarn bundles exist at the connection between the blade body and the edge plate, thereby enhancing the strength of the manufactured blade.

[0037] The yarn bundle 100 includes warp yarn A and weft yarn B, which are composed of a plurality of fibers. The yarn bundle drawn out is the warp yarn A. The extension direction of the warp yarn A is defined as the length direction of the edge plate, that is, Figure 1 The X direction is shown; the thickness direction of the edge plate, that is, the radial direction of the blade or the Y direction.

[0038] The yarn bundle is one or more of carbon fiber, glass fiber, Kevlar fiber, polyimide fiber, and SiC fiber. It contains at least two layers of warp yarn in the thickness direction of the edge plate, and the multiple layers of fibers can be the same fiber or a mixture of different fibers. The drawn warp yarn contains at least two layers.

[0039] It should be noted that the weaving form of preparing the blade preform is usually represented by the term "weaving", and the weaving form in this application includes one or more of weaving, braiding, knitting or stitching.

[0040] Specific examples of preparing a blade preform by the above method include but are not limited to the following.

[0041] In the first embodiment, a yarn bundle is first used to weave a lower edge plate preform or an upper edge plate preform; then a portion of the yarn bundle is used to continue weaving a blade body preform to obtain a blade body preform, and then the portion of the yarn bundle is used to continue weaving an upper edge plate preform or a lower edge plate preform.

[0042] Specific as Figures 2 to 4 As shown, the upper edge plate preform 1 is woven first as an example. The edge plate is woven along the length direction, that is, the two ends of the X direction are woven toward the middle direction. Figure 2 As shown, the first top warp yarn bundle 20 and the second top warp yarn bundle 30 are respectively combined and woven with the bottom warp yarn bundle 40. More specifically, the two layers of warp yarns J1-2 and J2-2 of the first top warp yarn bundle 20 are woven together with J3 and J4 of the bottom warp yarn bundle 40 at the left end of the bottom warp yarn bundle 40. In the same way, the two layers of warp yarns J1-1 and J2-1 of the second top warp yarn bundle 30 are woven together with J3 and J4 of the bottom warp yarn bundle 4 at the right end of the bottom warp yarn bundle 40.

[0043] When weaving to the connection position between the blade body and the edge plate, the number of warp yarns, the number of warp yarn layers and the weaving / braiding structure are selected and adjusted in the two top warp yarn bundles and the bottom warp yarn bundles according to the thickness of the blade body and the edge plate and the required interlayer strength of the preform.

[0044] Specifically, due to the difference in radius between the inner and outer chamfers at the connection between the blade and the edge plate, different requirements are placed on the inner and outer yarn bundles. Figure 6 As shown, the outer side W of the connection between the blade body and the edge plate is also the upper surface of the lead-out yarn bundle, and the inner side N is also the lower surface of the lead-out yarn bundle.

[0045] In order to ensure that the deformation difference of the fiber yarn bundles on the inner and outer sides of the preform at the connection is small, and the inner warp yarn has enough margin to form a chamfer, in some embodiments, at the connection between the edge plate preform and the blade body preform, the number of warp and weft yarn interlacing points on the upper surface of the lead-out yarn bundle is greater than the number of warp and weft yarn interlacing points on the lower surface of the lead-out yarn bundle. The denser the warp and weft yarn interlacing points, the more stable the place can be, and deformation can be avoided. Preferably, the number of warp and weft yarn interlacing points gradually decreases from the upper surface to the lower surface.

[0046] In some embodiments, at the connection between the edge plate preform and the blade body preform, the number of weft yarns K bundles near the upper surface and the upper surface of the yarn bundles drawn out is greater than the number of weft yarns K bundles near the lower surface and the lower surface. K bundles refer to the number of yarn bundles composed of multiple yarns. The larger the number, the less likely this part is to deform.

[0047] It is understood that in some embodiments, at the connection between the edge plate preform and the blade body preform, the diameter of the weft yarn of the lead-out yarn bundle close to the upper surface and the upper surface is greater than the diameter of the weft yarn close to the lower surface and the lower surface. The increase in diameter can also improve the strength of the outer connection part.

[0048] The selected bottom warp yarn bundle is continued to be woven to form an edge plate, and the two selected upper fiber layers are respectively lifted at a certain angle along the length direction of the edge plate to form the warp yarn bundle for weaving the blade body. For example, when the yarn bundle is woven to the position where the blade body is connected to the upper edge plate, J1-2, J2-2 and J1-1, J2-1 are lifted to lead out this part of the yarn bundle. J3 and J4 of the bottom warp yarn bundle 40 continue to be woven with the weft yarn B to form a complete upper edge plate preform 1. J1-2 and J2-2 of the lifted first top warp yarn bundle 20 are woven together, and J1-1 and J2-1 of the lifted second top warp yarn bundle 30 are woven together to form the chamfers 6 and 7 on both sides between the blade body preform 5 and the upper edge plate preform 1, as shown in FIG. Figure 3 shown.

[0049] After the chamfers on both sides are completed, J1-2, J2-2 of the first top warp yarn bundle 20 and J1-1, J2-1 of the second top warp yarn bundle 30 are further lifted until they are at a certain angle with the upper edge plate. J1-2, J2-2, J1-1, and J2-1 are woven together to form a blade body preform 5, as shown in FIG. Figure 3 shown.

[0050] After completing the weaving of the blade preform 5, J1-2, J2-2 of the first top warp yarn bundle 20 and J1-1, J2-1 of the second top warp yarn bundle 30 are respectively deflected toward the outside of the blade preform 5, and the deflection angle can be the chamfer β between the blade 11 and the lower edge plate 13, or it can be directly 90°, preferably ≥30°, to continue to lead out this part of the yarn bundle.

[0051] The J1-2 and J2-2 of the first top warp yarn bundle 20 are matched with the J5, J6, J7, J8, J9, and J10 of the bottom warp yarn bundle 80 of the lower edge plate 13, and are woven toward the left end of the lower edge plate 13. The J1-1 and J2-1 of the second top warp yarn bundle 30 are woven with the J5, J6, J7, J8, J9, and J10 of the bottom warp yarn bundle 80 of the lower edge plate 12 toward the right end of the lower edge plate 13, and finally a complete lower edge plate preform 9 is formed, as shown in FIG. Figure 4 shown.

[0052] In this way, the preparation of the whole blade preform is completed in the order of the upper edge plate preform 1, the blade body preform 5 and the lower edge plate preform 9. Then, the wrapped blade preform and the mold are heated and heated by an oven, a press, an autoclave, self-heating or any other appropriate heating method, and a liquid resin is introduced into the mold cavity using a suitable liquid molding process, and the resin is cured by heating, pressurizing, vacuuming or any other appropriate process method, and the cured blade is demoulded, and the subsequent processing is completed to obtain the blade.

[0053] In the second embodiment, yarn bundles are used to weave a lower edge plate preform or an upper edge plate preform, a portion of the yarn bundles are drawn out to continue weaving a blade body preform to obtain a blade body preform, a portion of the yarn bundles of the blade body preform are drawn out, and the upper edge plate preform or the lower edge plate preform is continued to be weaved.

[0054] That is, compared with the first embodiment, the difference of the second embodiment is that when the yarn bundles of the blade body preform 5 are led out, the yarn bundles extended when the edge plate preform is prepared before are not selected, that is, J1-2, J2-2 of the first top warp yarn bundle 20 and J1-1, J2-1 of the second top warp yarn bundle 30, but other yarn bundles used in preparing the blade body preform 5, such as J50, are selected.

[0055] In the third embodiment, the lower edge plate yarn bundle is first used to weave the lower edge plate preform, and the upper edge plate yarn bundle is used to weave the upper edge plate preform, and then a part of the lower edge plate yarn bundle and a part of the upper edge plate yarn bundle are combined to weave the blade body preform.

[0056] Furthermore, a portion of the lower edge plate yarn bundles led out can be woven into a first blade preform section, a portion of the upper edge plate yarn bundles led out can be woven into a second blade preform section, and the first blade preform section and the second blade preform section can be combined and woven into the blade preform, and the yarn bundle arrangement of the blade preform includes but is not limited to one or more of stacking in sequence, interleaving at intervals, and alternating interleaving.

[0057] The first blade preform subdivision and the second blade preform subdivision are only schematically described and do not represent the only number. Figure 5 In the illustrated embodiment, the yarn bundles led out on the left and right sides of the lower edge plate preform can respectively form two first blade preform sections, together with the two second blade preform sections formed by the yarn bundles led out on the left and right sides of the upper edge plate preform, that is, a total of four blade preform sections together form a blade preform.

[0058] Specific as Figure 5As shown, first, the manufacture of the upper edge plate preform 1' and the lower edge plate preform 9' is completed, and then the first blade warp yarn bundles J11-1, J11-2, J12-1, J12-2 of the upper edge plate preform 1' and the second blade warp yarn bundles J13-1, J13-2, J14-1, J14-2 of the lower edge plate preform 9' are combined together. The upper edge plate yarn bundles and the lower edge plate yarn bundles, a total of four blade warp yarn bundles, can be combined together in various forms, including but not limited to sequential stacking, interleaved interpolation, and alternating interpolation.

[0059] The warp yarns are then woven together using the weft yarns B to finally form a blade body preform 5'.

[0060] After the upper edge plate preform 1', the lower edge plate preform 9' and the blade body preform 5' are prepared, the wrapped blade preform and the mold are heated, and a suitable liquid molding process is used to introduce liquid resin into the cavity, and the resin is solidified by heating, pressurizing, vacuuming or any other appropriate process method, and the solidified blade is demoulded to complete subsequent processing to obtain the blade.

[0061] The above method not only connects the inside of the blade body and between the blade body and the edge plate with matrix material, but also with fibers, which can improve the interlayer strength inside the blade body and between the blade body and the edge plate, reduce the probability of failure at the interface between each layer, and improve the safety and stability of the blade structure. Therefore, it can significantly improve the strength between the blade body and the upper and lower edge plates of the blade, ensuring the stability and safety of the system.

[0062] The present application uses specific words to describe the embodiments of the present application. For example, "one embodiment", "an embodiment", and / or "some embodiments" refer to a certain feature, structure or characteristic related to at least one embodiment of the present application. Therefore, it should be emphasized and noted that "one embodiment" or "an embodiment" or "an alternative embodiment" mentioned twice or multiple times in different positions in this specification does not necessarily refer to the same embodiment. In addition, some features, structures or characteristics in one or more embodiments of the present application can be appropriately combined.

[0063] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for preparing a composite blade, for preparing a blade using a composite material, wherein the blade comprises a blade body, an upper edge plate and a lower edge plate, and is characterized in that: The method comprises the following steps: Weaving an upper edge plate preform or a lower edge plate preform using a yarn bundle; Leading out a portion of the yarn bundles, so that the partially led-out yarn bundles continue to weave the blade body preform; After obtaining a blade preform formed by an upper edge plate preform, a lower edge plate preform and a blade body preform, wrapping the blade preform with a mold; The blade preform is heated to a high temperature, resin is injected into the mold cavity of the mold, and the blade is formed after being cured and demoulded.

2. The method for preparing a composite blade according to claim 1, characterized in that: The lower edge plate preform is weaved using the lower edge plate yarn bundle, and the upper edge plate preform is weaved using the upper edge plate yarn bundle, so that a portion of the lower edge plate yarn bundle and a portion of the upper edge plate yarn bundle are combined to weave the blade body preform.

3. The method for preparing a composite blade according to claim 2, characterized in that: A portion of the lower edge plate yarn bundle is weaved to form a first blade preform section, a portion of the upper edge plate yarn bundle is weaved to form a second blade preform section, and the first blade preform section and the second blade preform section are combined and weaved into the blade preform.

4. The method for preparing a composite blade according to claim 2, characterized in that: The yarn bundle arrangement mode of the blade body preform includes one or more of sequential stacking, interleaved insertion and alternately inserted insertion.

5. The method for preparing a composite blade according to claim 1, characterized in that: Using the yarn bundle to weave a lower edge plate preform or an upper edge plate preform, Lead out a part of the yarn bundle to continue weaving the blade body preform, The drawn-out part of the yarn bundle is continuously used to continue weaving the upper edge plate preform or the lower edge plate preform.

6. The method for preparing a composite blade according to claim 1, characterized in that: Using the yarn bundle to weave a lower edge plate preform or an upper edge plate preform, Lead out a part of the yarn bundle to continue weaving the blade body preform, A portion of the yarn bundles of the blade body preform are led out, and the upper edge plate preform or the lower edge plate preform is continued to be woven.

7. The method for preparing a composite blade according to claim 5 or 6, characterized in that: Using the yarn bundle to weave from both ends of the upper edge plate preform or the lower edge plate preform along the length direction to obtain at least part of the upper edge plate preform or at least part of the lower edge plate preform; The surface yarn bundle for preparing the upper edge plate preform or the lower edge plate preform is lifted and drawn out, and combined with other yarn bundles to form a blade body yarn bundle to weave the blade body preform; The yarn bundle for preparing the surface layer of the blade body preform is lifted and drawn out, and combined with other yarn bundles to weave the lower edge plate preform or the upper edge plate preform.

8. The method for preparing a composite blade according to claim 1, characterized in that: The drawn-out part of the yarn bundle forms an angle with the undrawn yarn bundle.

9. The method for preparing a composite blade according to claim 8, characterized in that: The angle is ≥30°.

10. The method for preparing a composite blade according to claim 1, characterized in that: The yarn bundle is one or more of carbon fiber, glass fiber, Kevlar fiber, polyimide fiber and SiC fiber.

11. The method for preparing a composite blade according to claim 1, characterized in that: The yarn bundle includes warp yarn and weft yarn, and the yarn bundle drawn out is the warp yarn.

12. The method for preparing a composite blade according to claim 1, characterized in that: The yarn bundles used to prepare the upper edge plate preform and the lower edge plate preform are at least two layers, and the yarn bundles drawn out are at least one layer.

13. The method for preparing a composite blade according to claim 1, characterized in that: The number of yarn bundles, the number of layers and the weaving structure are selected and adjusted according to the thickness of the blade body and the edge plate and the interlayer strength of the preform.

14. The method for preparing a composite blade according to claim 13, characterized in that: At the connection between the edge plate preform and the blade body preform, the number of warp and weft interlacing points on the upper surface of the lead-out yarn bundle is greater than the number of warp and weft interlacing points on the lower surface of the lead-out yarn bundle.

15. The method for preparing a composite blade according to claim 13, characterized in that: At the connection between the edge plate preform and the blade body preform, the number of weft yarns K bundles close to the upper surface and the upper surface of the lead-out yarn bundles is greater than the number of weft yarns K bundles close to the lower surface and the lower surface.

16. The method for preparing a composite blade according to claim 13, characterized in that: At the connection between the edge plate preform and the blade body preform, the diameter of the weft yarn of the lead-out yarn bundle close to the upper surface and the upper surface is greater than the diameter of the weft yarn close to the lower surface and the lower surface.

17. The method for preparing a composite blade according to claim 1, characterized in that: The weaving method for preparing the blade preform includes one or more of weaving, braiding, knitting or stitching.

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