Dot matrix composite structure thermal protection air rudder for high-speed aircraft

Abstract

The invention discloses a lattice composite structure thermal protection air rudder for a high-speed aircraft and a manufacturing method, and the manufacturing method comprises the steps: 1, according to the thermal environment conditions and load conditions of the aircraft and the response characteristic requirements of the air rudder, a rudder shaft and a control surface of a metal framework are determined, the rudder shaft adopts a solid structure, and the control surface adopts a lattice structure; 2, according to the thermal environment condition of the aircraft, in combination with the temperature resistance of the metal framework, a composite material heat-proof structure is determined, and the control surface is coated with the composite material heat-proof structure, and the lattice structure is completely filled with the composite material heat-proof structure; 3, a metal framework is manufactured through a selective laser melting additive manufacturing process; and 4, the composite material heat-proof structure is manufactured through a resin transfer molding forming technology or an integrated mold pressing technology. The problem that a traditional air rudder is limited in the aspects of weight, structural efficiency, heat conduction management and the like is solved.

Description

Technical Field

[0001] The present invention relates to a lattice composite structure heat protection air rudder for high-speed aircraft and a manufacturing method thereof, in particular to a lattice composite heat protection air rudder integrating structural bearing and heat protection, and relates to the field of heat protection and structural design and manufacturing of air rudders for high-speed aircraft. Background Art

[0002] In high-speed aircraft, air rudders, as key control mechanisms, not only have to bear huge aerodynamic loads, but also face the test of high temperature environments. Traditional air rudder designs often use a layered structure, that is, separating the non-metallic heat protection layer and the metal load-bearing structure. Although this method can provide certain heat protection, it has great limitations in weight, structural efficiency and heat conduction management; on the other hand, air rudders made of carbon / silicon carbide material systems face problems such as poor impact resistance and difficult cost control, which are difficult to meet the requirements of modern high-speed aircraft for lightweight, high performance and low cost. Summary of the invention

[0003] The technical problem to be solved by the present invention is: to overcome the shortcomings of the prior art, solve the limitations of traditional air rudders in terms of weight, structural efficiency and heat conduction management, and propose a lattice composite structure thermal protection air rudder and manufacturing method for high-speed aircraft, aiming to achieve lightweight design while significantly improving thermal protection performance to adapt to structural integrity and control performance in extreme thermal environments, while meeting the requirements of low-cost production.

[0004] The purpose of the present invention is achieved through the following technical solutions:

[0005] In a first aspect, the present invention provides a method for manufacturing a lattice composite structure heat protection air rudder for a high-speed aircraft, wherein the lattice composite structure heat protection air rudder comprises a metal frame and a composite material heat protection structure, and the manufacturing method comprises:

[0006] Step 1: According to the aircraft thermal environment conditions, load conditions and the response characteristics of the air rudder, determine the rudder shaft and rudder surface of the metal frame. The rudder shaft adopts a solid structure and the rudder surface adopts a lattice structure;

[0007] Step 2: According to the thermal environment conditions of the aircraft and the temperature resistance of the metal frame, determine the composite heat protection structure, which covers the control surface and completely fills the lattice structure;

[0008] Step 3: Use laser selective melting additive manufacturing process to manufacture the metal skeleton;

[0009] Step 4: Use a resin transfer molding process or an integrated molding process to manufacture the composite material heat protection structure.

[0010] In combination with the first aspect, in one embodiment of the present invention, the metal skeleton is formed into an integral part by arranging the rudder surface unit cells and selecting the unit cell dimensions to meet the requirements of the air rudder for anti-bending and anti-torsion loads and weight distribution.

[0011] In combination with the first aspect, in one embodiment of the present invention, for the metal skeleton, in the stress concentration area, the stress concentration degree is reduced by increasing the fillet radius; for the parts with insufficient stiffness, the unit cell rod diameter is increased to improve the stiffness.

[0012] In combination with the first aspect, in one embodiment of the present invention, the metal skeleton is made of one of the following materials: aluminum alloy, titanium alloy, high-temperature alloy, stainless steel, and titanium-aluminum intermetallic compound.

[0013] In combination with the first aspect, in one embodiment of the present invention, the cell configuration of the lattice structure adopts one of body-centered cubic, face-centered cubic, and close-packed hexagonal.

[0014] In combination with the first aspect, in one embodiment of the present invention, the envelope size of the cell size and the rod diameter of the lattice structure are adjustable.

[0015] In combination with the first aspect, in one embodiment of the present invention, a detailed thermal analysis of the composite material thermal protection structure and the metal skeleton is performed using thermal analysis software to calculate the temperature distribution and thermal stress. The material selection and thickness distribution of the composite material thermal protection structure are adjusted based on the analysis results. The shape of the composite material thermal protection structure meets the aerodynamic shape requirements of the aircraft.

[0016] In combination with the first aspect, in one embodiment of the present invention, the composite heat-resistant structural material is made of short-cut fiber reinforced high-temperature resistant resin-based composite material.

[0017] In combination with the first aspect, in one embodiment of the present invention, for the situation where the installation space of the lattice composite structure thermal protection air rudder is limited, the rudder surface is divided into two parts along the vertical rudder axis, each part is manufactured independently and then connected with a folding structure.

[0018] In a second aspect, the present invention provides a lattice composite structure thermal protection air rudder for high-speed aircraft. The lattice composite structure thermal protection air rudder comprises a metal frame and a composite material thermal protection structure, and is manufactured using the manufacturing method described in the first aspect.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] (1) The present invention achieves lightweighting of the air rudder through the optimized design of the lattice main load-bearing structure and the low-density characteristics of the composite material, significantly reducing the overall weight of the aircraft and improving fuel efficiency and range.

[0021] (2) The present invention can improve the efficiency of thermal protection. The selection of different composite materials can effectively cope with the extreme thermal environment during high-speed flight and ensure the structural safety of the aircraft.

[0022] (3) The present invention is integrally molded to enhance structural integrity and controllability, thereby improving the maneuverability and reliability of the aircraft.

[0023] (4) The present invention can adopt a folding design to increase the applicability of the air rudder in different application scenarios and broaden its scope of application. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 Schematic diagram of the metal skeleton.

[0025] Figure 2 Schematic diagram of the composite material heat protection structure.

[0026] Figure 3 Schematic diagram of the thermal protection air rudder with lattice composite structure.

[0027] Figure 4 It is a schematic diagram of a partial cross-section of a thermal protection air rudder with a lattice composite structure. DETAILED DESCRIPTION

[0028] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0029] A method for manufacturing a lattice composite structure heat protection air rudder for high-speed aircraft, the lattice composite structure heat protection air rudder comprising a metal frame and a composite material heat protection structure, the manufacturing method comprising:

[0030] Step 1: The metal frame includes the rudder shaft and the rudder surface, such as Figure 1 As shown in the figure, the rudder shaft and the rudder surface are integrated designs, in which the rudder shaft adopts a solid structure and the rudder surface adopts a lattice structure. Specifically, according to the thermal environment conditions, load conditions and response characteristics of the aircraft, the metal skeleton is designed as a whole, considering the influence of the composite material heat protection structure on the stiffness and weight, and by reasonably arranging the rudder surface unit cells and selecting the appropriate unit cell size, the requirements of the air rudder for anti-bending and anti-torsion loads and weight distribution can be met. According to the results of mechanical analysis, the structural parameters, dimensional parameters, material distribution, etc. of the metal skeleton can be optimized and adjusted. For example, in the stress concentration area, the stress concentration degree can be reduced by increasing the fillet radius and other measures; for the parts with insufficient stiffness, the unit cell rod diameter can be appropriately increased to improve the overall stiffness of the structure. At the same time, in the optimization process, the optimal balance point of various performance indicators such as weight, strength, and stiffness should be comprehensively considered.

[0031] The metal skeleton material system can be selected from aluminum alloy, titanium alloy, high-temperature alloy, stainless steel, titanium-aluminum intermetallic compounds, etc. according to the service temperature, weight, strength and stiffness requirements.

[0032] The rudder surface lattice structure can adopt cell structures of different configurations and sizes according to the center of mass and weight requirements, wherein the adoptable cell configurations include but are not limited to body-centered cubic, face-centered cubic, close-packed hexagonal, etc., and the adjustable cell sizes include envelope size and rod diameter, etc.

[0033] Step 2: Design the composite heat protection structure according to the aircraft thermal environment conditions and the temperature resistance level of the metal frame. Use thermal analysis software to conduct detailed thermal analysis of the composite heat protection structure and metal frame, calculate the temperature distribution and thermal stress, and optimize the structural material selection and thickness distribution of the composite heat protection structure according to the analysis results. During the optimization process, the mutual influence of various factors such as weight, thermal insulation performance, and mechanical strength should be comprehensively considered to find the best balance point. During the design, the composite material completely fills the lattice structure, and the shape meets the aerodynamic shape requirements of the aircraft, such as Figures 2 to 4 shown.

[0034] Composite heat-resistant structural materials can be made of short-cut fiber reinforced high-temperature resistant resin-based composite materials, or other composite materials.

[0035] Step 3: Metal skeleton manufacturing. The metal skeleton is formed in one piece using the laser selective melting additive manufacturing process. After forming, it is heat treated, wire cut, support removed, polished and sandblasted to complete the metal skeleton manufacturing.

[0036] Step 4: Manufacturing of composite heat-resistant structure. The composite heat-resistant structure adopts resin transfer molding process or integrated compression molding process to ensure seamless combination of external heat-resistant structural materials and lattice load-bearing structure.

[0037] Furthermore, for some aircraft, the installation space of their air rudders is limited, so the rudder surface can be divided into two halves along the vertical rudder axis, manufactured separately using a metal frame + composite material heat protection structure, and then connected using a folding structure to facilitate storage and deployment, thereby improving operational flexibility.

[0038] Furthermore, a metal skeleton is selected as the main load-bearing structure, and the lattice cells can be selected from body-centered cubic, face-centered cubic, close-packed hexagonal and other configurations according to the load requirements. The cell size and rod diameter can be adjusted according to the load and weight requirements, and a single cell filling or variable density cell filling can be used. The material system can be selected from aluminum alloy, titanium alloy, high-temperature alloy, stainless steel, titanium-aluminum intermetallic compound, etc. according to the service temperature, weight, strength and stiffness requirements.

[0039] Furthermore, the composite heat-resistant structure uses composite materials as fillers, and also plays an auxiliary load-bearing function, and its outer surface is the aerodynamic shape of the air rudder. The material can be short-cut fiber reinforced high-temperature resistant resin-based composite materials, or other composite materials can be selected.

[0040] Furthermore, the present invention adopts a foldable design, giving full play to the advantage of the strong designability of the metal frame. For specific application scenarios, the air rudder has a foldable function, which is convenient for storage and deployment, and improves operational flexibility.

[0041] Furthermore, in the molding process of the present invention, the metal skeleton is integrally manufactured by laser selective melting (SLM) additive manufacturing technology, and then RTM or integrated molding process is used to ensure seamless integration of the composite heat protection structure and the lattice load-bearing structure, which on the one hand strengthens the mutual transmission of mechanical loads between the two, and on the other hand reduces the thermal bridge effect and improves the overall performance.

[0042] A lattice composite structure heat protection air rudder for high-speed aircraft, comprising a metal frame and a composite material heat protection structure, and is manufactured using the above-mentioned manufacturing method.

[0043] On the one hand, the present invention utilizes the advantage of good toughness of metal structures to compensate for the low mechanical properties of composite materials, especially the low tensile properties and impact resistance; on the other hand, it fully utilizes the mechanical and heat-insulating properties of chopped fiber reinforced resin-based composite materials to achieve an integrated load-bearing and heat-insulating design, thereby ensuring the overall heat-insulating and mechanical properties of the air rudder.

[0044] The contents not described in detail in the specification of the present invention belong to the common knowledge of those skilled in the art.

[0045] Although the present invention has been disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and modifications made to the above embodiments based on 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 of the technical solution of the present invention.

Claims

1. A method for manufacturing a lattice composite structure thermal protection air rudder for high-speed aircraft, characterized in that: The lattice composite structure heat protection air vane comprises a metal frame and a composite material heat protection structure, and the manufacturing method comprises: Step 1: According to the aircraft thermal environment conditions, load conditions and the response characteristics of the air rudder, determine the rudder shaft and rudder surface of the metal frame. The rudder shaft adopts a solid structure and the rudder surface adopts a lattice structure; Step 2: According to the thermal environment conditions of the aircraft and the temperature resistance of the metal frame, determine the composite heat protection structure, which covers the control surface and completely fills the lattice structure; Step 3: Use laser selective melting additive manufacturing process to manufacture the metal skeleton; Step 4: Use a resin transfer molding process or an integrated molding process to manufacture the composite material heat protection structure.

2. The method for manufacturing a lattice composite structure thermal protection air rudder according to claim 1, characterized in that: For the metal frame, by arranging the rudder surface unit cells and selecting the unit cell dimensions, the requirements of the air rudder for anti-bending, anti-torsion loads and weight distribution are met, and the rudder shaft and the rudder surface are formed in one piece.

3. The method for manufacturing a lattice composite structure thermal protection air rudder according to claim 1, characterized in that: For metal skeletons, in stress concentration areas, the stress concentration degree is reduced by increasing the fillet radius; for areas with insufficient stiffness, the unit cell rod diameter is increased to improve the stiffness.

4. The method for manufacturing a lattice composite structure thermal protection air rudder according to claim 1, characterized in that: The metal skeleton is made of one of the following materials: aluminum alloy, titanium alloy, high-temperature alloy, stainless steel, and titanium-aluminum intermetallic compound.

5. The method for manufacturing a lattice composite structure thermal protection air vane according to claim 1, characterized in that: The cell configuration of the lattice structure adopts one of body-centered cubic, face-centered cubic and close-packed hexagonal.

6. The method for manufacturing a lattice composite structure thermal protection air vane according to claim 1, characterized in that: The envelope size of the cell size and the rod diameter of the lattice structure are adjustable.

7. The method for manufacturing a lattice composite structure thermal protection air vane according to claim 1, characterized in that: For the composite thermal protection structure, thermal analysis software is used to conduct detailed thermal analysis of the composite thermal protection structure and metal skeleton, calculate the temperature distribution and thermal stress, and adjust the material selection and thickness distribution of the composite thermal protection structure based on the analysis results; the shape of the composite thermal protection structure meets the aerodynamic shape requirements of the aircraft.

8. The method for manufacturing a lattice composite structure thermal protection air vane according to claim 1, characterized in that: The composite heat-resistant structural material is made of short-cut fiber reinforced high-temperature resistant resin-based composite material.

9. The method for manufacturing a lattice composite structure thermal protection air vane according to claim 1, characterized in that: As for the situation where the installation space of the thermal protection air rudder with lattice composite structure is limited, the rudder surface is divided into two parts along the vertical rudder axis. Each part is manufactured independently and then connected with a folding structure.

10. A lattice composite structure thermal protection air rudder for high-speed aircraft, characterized in that: The lattice composite structure thermal protection air vane comprises a metal frame and a composite material thermal protection structure, and is manufactured using the manufacturing method described in any one of claims 1 to 9.

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