Method of manufacturing a composite blade

Abstract

The application provides a composite blade manufacturing method for manufacturing a blade using a composite material, the blade comprising a blade body, an upper edge plate and a lower edge plate, the method comprising the following steps: weaving an upper edge plate preform or a lower edge plate preform using a yarn bundle; leading out a part of the yarn bundle, and continuing to weave a blade body preform using the part of the yarn bundle; after obtaining a blade preform formed by the upper edge plate preform, the lower edge plate preform and the blade body preform, wrapping the blade preform using a mold; heating the blade preform, injecting resin into a cavity of the mold, and forming the blade after curing and demolding. The blade manufactured by the method has better stability and safety.

Description

Technical Field

[0001] This invention relates to the field of aero-engines, and more specifically to the field of blade manufacturing. Background Technology

[0002] To further improve the efficiency and reduce fuel consumption of turbofan engines, increasing the bypass ratio is an effective technical approach. However, this increased bypass ratio leads to larger dimensions for the fan blades, casing, and outer bypass exit vanes (OGV), resulting in a higher proportion of the fan section's weight relative to the total engine weight, or an increase in the overall engine mass. Therefore, to meet the requirements for low fuel consumption and enhance the market competitiveness of engines for large buses, engine weight reduction has become a primary objective for major engine manufacturers.

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

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

[0005] One object of the present invention is to provide a method for preparing blades, the resulting blades having better stability and safety.

[0006] A method for preparing composite material blades to achieve the above objectives is used to prepare blades using composite materials. The blades include a blade body, an upper edge plate, and a lower edge plate. The method includes the following steps: weaving an upper edge plate preform or a lower edge plate preform using yarn bundles; drawing out a portion of the yarn bundles and continuing to weave the drawn-out yarn bundles into a blade body preform; obtaining a blade preform formed by the upper edge plate preform, the lower edge plate preform, and the blade body preform; wrapping the blade preform with a mold; heating the blade preform; injecting resin into the cavity of the mold; and curing and demolding to form a blade.

[0007] In one or more embodiments, a lower edge plate preform is woven using a lower edge plate yarn bundle, and an upper edge plate preform is woven using an upper edge plate yarn bundle, such 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 leaf preform.

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

[0009] In one or more embodiments, the yarn bundles of the leaf preform are arranged in one or more ways, including sequential stacking, intermittent insertion, and alternating insertion.

[0010] In one or more embodiments, the yarn bundle is used to weave the lower edge plate preform or the upper edge plate preform, a portion of the yarn bundle is drawn off to continue weaving the leaf preform, and the drawn-off portion of the yarn bundle is used to continue weaving the upper edge plate preform or the lower edge plate preform.

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

[0012] In one or more embodiments, the yarn bundles are used 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 a portion of the upper edge plate preform or at least a portion of the lower edge plate preform; the surface yarn bundles used to prepare the upper edge plate preform or the lower edge plate preform are lifted out and combined with other yarn bundles to form a leaf body yarn bundle to weave the leaf body preform; the surface yarn bundles used to prepare the leaf body preform are lifted 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 drawn-out yarn bundle forms an angle with the undrawn yarn bundle.

[0014] In one or more embodiments, the included 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, with the drawn yarn bundle being the warp yarns.

[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 based on the thickness of the leaf blade and the edge plate, as well as the interlayer strength of the preform.

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

[0020] In one or more embodiments, at the connection between the flange preform and the blade preform, the K bundle of the weft yarn near the upper surface and the upper surface is greater than the K bundle of the weft yarn near the lower surface and the lower surface.

[0021] In one or more embodiments, at the connection between the edge plate preform and the blade preform, the diameter of the weft yarns near the upper surface and the upper surface of the yarn bundle is greater than the diameter of the weft yarns near 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 sewing.

[0023] The aforementioned composite blade preparation method allows for the direct weaving of the blade preform using drawn yarn bundles during the blade preform preparation process. This results in yarn bundles at the connection between the blade and the fin, ensuring that the blade body and the fin are connected not only by the matrix material but also by fibers. This enhances the interlayer strength within the blade body and between the blade and the fin, reduces the probability of interlayer interface failure, and improves the safety and stability of the blade structure. Attached Figure Description

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

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

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

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

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

[0029] Figure 5 This is a schematic diagram of the process of preparing the leaf preform together using the upper edge plate yarn bundle and the lower edge plate yarn bundle;

[0030] Figure 6 This is a schematic diagram of the outer and inner yarn bundles at the connection between the rim plate preform and the blade preform;

[0031] Figure 7 This is a flowchart of the composite material blade preparation method. Detailed Implementation

[0032] The present invention will be further described below with reference to specific embodiments and accompanying drawings. More details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention can obviously be implemented in many other ways different from those described herein. Those skilled in the art can make similar extensions and derivations based on actual application situations without departing from the spirit of the present invention. Therefore, the scope of protection of the present invention should not be limited by the content of this specific embodiment.

[0033] It should be noted that these and other accompanying drawings are merely examples and are not drawn to scale, and should not be construed as limiting the scope of protection of the present invention.

[0034] Figure 1 The stator blade structure includes a blade body 11, an upper edge plate 12, and a lower edge plate 13, with the upper edge plate 12 and lower edge plate 13 collectively referred to as edge plates. During the fabrication of the 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. The combination of the blade body preform 5, the upper edge plate preform 1, and the lower edge plate preform 9 constitutes the blade preform.

[0035] The method for preparing composite material blades disclosed herein is used to prepare blades using composite materials, comprising the following steps: weaving an upper edge plate preform or a lower edge plate preform using a yarn bundle 100; drawing out a portion of the yarn bundle 100 so that the drawn-out yarn bundle continues to weave a blade preform; after obtaining a blade preform formed by the upper edge plate preform, the lower edge plate preform, and the blade preform, wrapping the blade preform with a mold; heating the blade preform to a higher temperature, injecting resin into the cavity of the mold, and forming a blade after curing and demolding.

[0036] By using the drawn yarn bundles to weave together during the preparation of the blade preform and the rim plate preform, yarn bundles are present at the connection between the blade and the rim plate, thereby enhancing the strength of the manufactured blade.

[0037] Yarn bundle 100 includes warp yarn A and weft yarn B, composed of numerous fibers. The drawn yarn bundle is warp yarn A. The extension direction of 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 rim 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 yarns in the thickness direction of the edge plate; these layers can be made of the same fiber or a mixture of different fibers. The drawn warp yarns contain at least two layers.

[0039] It should be noted that the weaving method used to prepare the blade preform is commonly referred to as "weaving". In this application, the weaving method includes one or more of machine weaving, braiding, knitting or sewing.

[0040] Specific embodiments of preparing blade preforms using the above method include, but are not limited to, the following.

[0041] In the first embodiment, the lower edge plate preform or the upper edge plate preform is first woven using yarn bundles; then, a portion of the yarn bundle is drawn out to continue weaving the leaf preform to obtain the leaf preform, and then the portion of the yarn bundle drawn out is used to continue weaving the upper edge plate preform or the lower edge plate preform.

[0042] Specifically, such as Figures 2 to 4 As shown, taking the prefabricated upper edge plate 1 as an example, the weaving proceeds along the length direction of the edge plate, that is, from both ends in the X direction towards the middle. Specifically, refer to... Figure 2 As shown, the first top warp bundle 20 and the second top warp bundle 30 are woven together with the bottom warp bundle 40. More specifically, the two layers of warp yarns J1-2 and J2-2 of the first top warp bundle 20 are woven together with J3 and J4 of the bottom warp bundle 40 at the left end of the bottom warp bundle 40. In the same manner, the two layers of warp yarns J1-1 and J2-1 of the second top warp bundle 30 are woven together with J3 and J4 of the bottom warp bundle 40 at the right end of the bottom warp bundle 40.

[0043] When weaving to the connection point between the leaf blade and the rim plate, the number of warp yarns, the number of warp layers, and the woven / knitted structure are selected and adjusted from the two top warp yarn bundles and the bottom warp yarn bundles, according to the thickness of the leaf blade and the rim plate and the required interlayer strength of the prefabricated body.

[0044] Specifically, due to the difference in radius between the inner and outer chamfers at the junction of the leaf blade and the sill plate, different requirements are placed on the inner and outer yarn bundles. For example... Figure 6 As shown, the outer W at the junction of the leaf blade and the edge plate is also the upper surface of the yarn bundle, and the inner N is also the lower surface of the yarn bundle.

[0045] To ensure minimal deformation differences between the inner and outer fiber bundles of the preform at the connection point, and to allow sufficient allowance for the inner warp yarns to form a chamfer, in some embodiments, the number of warp and weft yarn interlacing points on the upper surface of the yarn bundle at the connection point between the sill plate preform and the blade preform is greater than that on the lower surface. A denser interlacing of warp and weft yarns improves stability and prevents deformation. Preferably, the number of interlacing points gradually decreases from the upper to the lower surface.

[0046] In some embodiments, at the connection between the flange preform and the blade preform, the number of K bundles of weft yarns near the upper surface and the upper surface of the yarn bundle is greater than the number of K bundles of weft yarns near the lower surface and the lower surface. K bundle refers to the number of yarn bundles composed of multiple yarns. A larger number of K bundles makes the area less prone to deformation.

[0047] It is understood that, in some embodiments, at the connection between the flange preform and the blade preform, the diameter of the weft yarns near the upper surface and the upper surface of the yarn bundle is greater than the diameter of the weft yarns near the lower surface and the lower surface. This increased diameter can also improve the strength of the outer connection area.

[0048] The selected bottom warp bundles are continued to be woven to form the edge plate. The two selected upper fiber layers are lifted at certain angles along the length of the edge plate to become warp bundles for weaving the leaf body. When the bundles are woven to the position where the leaf body connects to the upper edge plate, J1-2, J2-2 and J1-1, J2-1 are lifted to draw out this part of the bundle. J3 and J4 of the bottom warp bundles 40 continue to be woven with the weft yarn B to form the complete upper edge plate preform 1. J1-2 and J2-2 of the first lifted top warp bundles 20 are woven together, and J1-1 and J2-1 of the second lifted top warp bundles 30 are woven together to form the chamfers 6 and 7 on both sides between the leaf body preform 5 and the upper edge plate preform 1. Figure 3 As shown.

[0049] After completing the chamfering on both sides, continue lifting J1-2 and J2-2 of the first top warp bundle 20 and J1-1 and J2-1 of the second top warp bundle 30 until they are at a certain angle to the upper edge plate. Weave J1-2, J2-2, J1-1, and J2-1 together to form the blade preform 5, as shown. Figure 3 As shown.

[0050] After the weaving of the leaf preform 5 is completed, the J1-2 and J2-2 of the first top warp bundle 20 and the J1-1 and J2-1 of the second top warp bundle 30 are deflected to the outside of the leaf preform 5. The deflection angle can be the chamfer β between the leaf 11 and the lower edge plate 13, or it can be 90°, preferably ≥30°, so as to continue to draw out this part of the yarn bundle.

[0051] The J1-2 and J2-2 layers of the first top warp bundle 20 are combined with the J5, J6, J7, J8, J9, and J10 layers of the bottom warp bundle 80 of the lower edge plate 13 and woven together to the left end of the lower edge plate 13. The J1-1 and J2-1 layers of the second top warp bundle 30 are then woven together with the J5, J6, J7, J8, J9, and J10 layers of the bottom warp bundle 80 of the lower edge plate 13 to the right end of the lower edge plate 13, ultimately forming a complete lower edge plate prefabricated body 9, as shown below. Figure 4 As shown.

[0052] Thus, following the sequence of upper edge plate preform 1, blade preform 5, and lower edge plate preform 9, the overall blade preform is prepared. The wrapped blade preform and mold are then heated using an oven, press, autoclave, self-heating, or any other suitable heating method. A suitable liquid molding process is used to introduce liquid resin into the mold cavity, and the resin is cured using heating, pressurization, vacuuming, or any other suitable process. The cured blade is then demolded, and subsequent processing is completed to obtain the blade.

[0053] In the second embodiment, a portion of the yarn bundle is used to weave the lower edge plate preform or the upper edge plate preform, and a portion of the yarn bundle is drawn out to continue weaving the leaf preform to obtain the leaf preform. A portion of the yarn bundle of the leaf preform is then drawn out to continue weaving the upper edge plate preform or the lower edge plate preform.

[0054] That is, compared with the first embodiment, the difference of the second embodiment is that when drawing out the yarn bundles of the leaf preform 5, the yarn bundles extended during the preparation of the rim plate preform, namely J1-2 and J2-2 of the first top warp yarn bundle 20 and J1-1 and J2-1 of the second top warp yarn bundle 30, are not selected. Instead, other yarn bundles used during the preparation of the leaf preform 5, such as J50, are selected.

[0055] In the third embodiment, the lower edge plate preform is first woven using the lower edge plate yarn bundle, the upper edge plate preform is woven using the upper edge plate yarn bundle, and then a portion of the lower edge plate yarn bundle and a portion of the upper edge plate yarn bundle are combined to weave the leaf preform.

[0056] Furthermore, a portion of the lower edge plate yarn bundle can be woven to form a first leaf body preform section, and a portion of the upper edge plate yarn bundle can be woven to form a second leaf body preform section. The first leaf body preform section and the second leaf body preform section can be combined and woven to form the leaf body preform. The yarn bundle arrangement of the leaf body preform includes, but is not limited to, one or more of the following: sequential stacking, intermittent insertion, and alternating insertion.

[0057] The first and second precast body sections are only illustrated and do not represent a unique quantity. Figure 5 In the embodiment shown, the yarn bundles drawn out from the left and right sides of the lower edge plate preform can respectively form two first blade preform parts, and together with the yarn bundles drawn out from the left and right sides of the upper edge plate preform, form two second blade preform parts, that is, a total of 4 blade preform parts together form the blade preform.

[0058] Specifically, such as Figure 5As shown, the upper edge plate preform 1' and the lower edge plate preform 9' are manufactured first. Then, the first leaf body warp bundles J11-1, J11-2, J12-1, J12-2 of the upper edge plate preform 1' and the second leaf body warp bundles J13-1, J13-2, J14-1, J14-2 of the lower edge plate preform 9' are combined together. The four leaf body warp bundles, including the upper edge plate warp bundles and the lower edge plate warp bundles, can be combined in various ways, including but not limited to sequential stacking, intermittent insertion, and alternating insertion.

[0059] Then, weft yarn B is used to weave these warp yarns together, finally forming the leaf preform 5'.

[0060] After obtaining the upper edge plate preform 1', lower edge plate preform 9' and blade preform 5', the wrapped blade preform and mold are heated, and liquid resin is introduced into the cavity using a suitable liquid molding process. The resin is then cured by heating, pressurizing, vacuuming or any other appropriate process method. The cured blade is then demolded, and subsequent processing is completed to obtain the blade.

[0061] The above method uses not only matrix material to connect the blade body and the blade edge plates, but also fibers to connect them. This can improve the interlayer strength between the blade body and the blade edge plates, reduce the probability of failure at the interlayer interfaces, 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, ensuring the stability and safety of the system.

[0062] This application uses specific terms to describe embodiments of the application. Terms such as "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic associated with at least one embodiment of the application. Therefore, it should be emphasized and noted that references to "an embodiment," "one embodiment," or "an alternative embodiment" in different locations throughout this specification do not necessarily refer to the same embodiment. Furthermore, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0063] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the invention, fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for preparing composite material blades, used to prepare blades using composite materials, said blade comprising a blade body, an upper edge plate, and a lower edge plate, characterized in that, The method includes the following steps: Use yarn bundles to weave the upper or lower edge prefabricated body; A portion of the yarn bundle is drawn out, and this portion of the drawn-out yarn bundle continues to weave the leaf preform; After obtaining the blade preform formed by the upper edge plate preform, the lower edge plate preform, and the blade preform, the blade preform is wrapped with a mold. The blade preform is heated to a certain temperature, resin is injected into the cavity of the mold, and after curing and demolding, a blade is formed. The portion of the yarn bundle pulled out forms an angle with the portion of the yarn bundle that was not pulled out; At the connection between the flange preform and the blade preform, the number of warp and weft yarn interlacing points on the outer surface of the yarn bundle is greater than the number of warp and weft yarn interlacing points on the inner surface of the yarn bundle, or At the connection between the flange preform and the blade preform, the K bundle of weft yarns near the outer surface and the outer surface of the yarn bundle is larger than the K bundle of weft yarns near the inner surface and the inner surface, or At the connection between the flange preform and the blade preform, the diameter of the weft yarn near the outer surface and the outer surface of the yarn bundle is greater than the diameter of the weft yarn near the inner surface and the inner surface.

2. The method for preparing composite material blades as described in claim 1, characterized in that, The lower edge plate preform is woven using the lower edge plate yarn bundle, and the upper edge plate preform is woven using the upper edge plate yarn bundle, such 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 leaf preform.

3. The method for preparing composite material blades as described in claim 2, characterized in that, A portion of the lower edge plate yarn bundle is woven to form a first blade preform portion, and a portion of the upper edge plate yarn bundle is woven to form a second blade preform portion. The first blade preform portion and the second blade preform portion are then combined and woven to form the blade preform.

4. The method for preparing composite material blades as described in claim 2, characterized in that, The arrangement of yarn bundles in the leaf preform includes one or more of the following: sequential stacking, intermittent insertion, and alternating insertion.

5. The method for preparing composite material blades as described in claim 1, characterized in that, The lower edge plate preform or the upper edge plate preform is woven using the aforementioned yarn bundles. A portion of the yarn bundle is drawn out to continue weaving the leaf preform. Continue using the portion of yarn that was pulled out to continue weaving the upper or lower edge preform.

6. The method for preparing composite material blades as described in claim 1, characterized in that, The lower edge plate preform or the upper edge plate preform is woven using the aforementioned yarn bundles. A portion of the yarn bundle is drawn out to continue weaving the leaf preform. A portion of the yarn bundle of the blade preform is drawn out and used to continue weaving the upper or lower edge plate preform.

7. The method for preparing composite material blades as described in claim 5 or 6, characterized in that, Using the yarn bundle, weave 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 bundles of the upper or lower edge plate preforms are lifted out and combined with other yarn bundles to form leaf body yarn bundles for weaving the leaf body preforms. The yarn bundles used to prepare the surface layer of the leaf preform are lifted 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 composite material blades as described in claim 1, characterized in that, The included angle is ≥30°.

9. The method for preparing composite material blades as described in claim 1, characterized in that, The yarn bundle is one or more of carbon fiber, glass fiber, Kevlar fiber, polyimide fiber, and SiC fiber.

10. The method for preparing composite material blades as described in claim 1, characterized in that, The yarn bundle includes warp yarns and weft yarns, and the yarn bundle drawn out is the warp yarn.

11. The method for preparing composite material blades as described in 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.

12. The method for preparing composite material blades as described in claim 1, characterized in that, The number of yarn bundles, the number of layers, and the weaving structure are selected and adjusted based on the thickness of the leaf blade and the edge plate, as well as the interlayer strength of the prefabricated body.

13. The method for preparing composite material blades as described in claim 1, characterized in that, The weaving method for preparing the blade preform includes one or more of the following: machine weaving, braiding, knitting, or sewing.

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