Rapid forming method of three-dimensional prefabricated body for hot end component

Abstract

The invention relates to a rapid forming method of a three-dimensional prefabricated body for a hot end component. The method comprises the steps that a three-dimensional CAD model of a double-blade integrally-formed prefabricated body is established according to the structural characteristics and performance requirements of a hot end component, layered slicing treatment is conducted, the material specification of fiber cloth is determined, partition design and partition forming are conducted on blades, two engine blades are formed at a time, and the hot end component is obtained. According to the specific structure parameters of the double-blade integrally-formed prefabricated body, the specification of fiber cloth in each area is determined, the appropriate length of a blade connecting area is selected, the specification and the layer number of insertion pieces needed by an insertion piece area are determined, and laying and insertion of the fiber cloth are completed according to a sewing mold. According to the forming method for forming the two engine blade components at a time, the manufacturing production efficiency of the engine blade is greatly improved, the manufacturing cost is reduced, the manufacturing period is shortened, meanwhile, the technology for forming the engine blade components through different fiber cloth is optimized, and the performance of the engine blade components is improved.

Description

Technical Field

[0001] This invention relates to the field of ceramic composite component forming, and more specifically to a rapid prototyping method for a three-dimensional preform for hot-end components. Background Technology

[0002] As engine performance requirements continue to increase, traditional high-temperature alloys are finding it difficult to meet the operating temperature and lightweight requirements of next-generation engines, leading to the increasingly widespread application of ceramic matrix composites in aero engines.

[0003] Most current engine blades employ a mortise and tenon structure, using tenons to connect the working blades to the rotor. During operation, the centrifugal force of the blades forces the supporting surfaces of all the teeth on the tenons of the aero-engine blade to press against the tenons of the rotor. This structure allows for better fixation of the blades to the engine fan; maintains dynamic balance during operation, achieving self-adjustment; minimizes the threat of vibration; and facilitates blade disassembly and replacement, reducing maintenance costs. The GE90 engine uses 22 composite material fan blades with a total mass of 349 kg, accounting for approximately 8% of the engine's total mass. Compared to hollow titanium alloy blades, this represents a 66% reduction in mass and a 100% increase in strength. The blades are manufactured using a compression molding process, and to prevent delamination during operation, micro-stitching technology is used to reinforce the trailing edge. The surface is coated with a wear-resistant material to reduce the coefficient of friction. Snecma has used RTM forming technology on the LEAP engine blades to create a three-dimensional blade preform. The successful application of various composite blade engines demonstrates that composite fan blades are suitable for the demanding requirements of commercial flight.

[0004] The development and application of composite aero-engine blades are still in their early stages. Therefore, future development requires more research to explore key issues such as the performance, application range, and stress state of composite aero-engine blades. At the same time, it is also necessary to study new processes and materials for new composite aero-engine blades to meet the requirements of high strength, ductility, corrosion resistance, wear resistance, and low cost. Summary of the Invention

[0005] This invention provides a rapid prototyping method for three-dimensional preforms of hot-end components, which mainly solves the problem of the difficulty in achieving rapid and low-cost manufacturing of composite material blade components for aero-engines.

[0006] To achieve the above objectives, according to one aspect of the present invention, a rapid manufacturing method for blade preforms is proposed, the specific steps of which are as follows:

[0007] a) Based on the blade shape and performance requirements, establish a three-dimensional CAD model of the prefabricated body with two blades integrally formed, and determine the material specifications of the fiber cloth and fiber.

[0008] b) The three-dimensional CAD model of the double-blade integrated precast body is partitioned to obtain the central area (1), blade reinforcement area (2), blade edge connection area (3), edge tenon connection area (4), and tenon insert area (5), and obtain data information such as the cross-sectional shape and thickness of different partitions;

[0009] c) The three-dimensional CAD models of the central area, blade reinforcement area, blade edge connection area, edge tenon connection area, and tenon insert area are sliced ​​into layers to obtain information such as the layer size and shape of the prefabricated body in different zones.

[0010] d) Determine the specifications and quantity of the insert fiber cloth required for the tenon insert area based on the angle dimension β and radius R at the blade root of the double-blade prefabricated body, and determine the number of lay-up layers, stitch spacing and stitch length for different zones;

[0011] e) Determine the number of fiber cloth layers based on the size requirements of the double-blade integrated precast body, and cut the specified fiber cloth according to the layer size and shape of the precast body in different zones;

[0012] f) Position and lay the fiber cloth in the central area, the blade reinforcement area on both sides of the central area, and the blade edge connection area in sequence. Use the specified continuous fiber bundle to sew the fiber cloth layers of the blade area containing the central area, the blade reinforcement area, and the blade edge connection area to obtain the blade at one end of the integrated prefabricated body of the double blade.

[0013] g) Repeat step f) to obtain the other end of the blade body of the one-piece preform of the double blades;

[0014] h) Number the pre-cut and prepared insert layer fiber cloth according to shape, specifications and quantity, and lay it in sequence with the already laid central area and leaf reinforcement area fiber until all insert fiber cloth is laid to obtain the tenon insert area.

[0015] i) After the fiber cloth for inserting the blades is laid, the fiber cloth for the tenon joint area is laid on the upper and lower sides of the tenon insert area. The two ends of the fiber cloth for the tenon joint area are fixed to the blade edges of the double blades respectively, wrapping the tenon insert area.

[0016] j) Based on the characteristics of the double-blade tenon structure, design and prepare an auxiliary sewing mold to fix the two ends of the double blades on the sewing mold, lock the upper and lower modules of the sewing mold, and fix the connecting layer module to the double tenon area of ​​the double-blade integral preform.

[0017] k) Use continuous fiber bundles to sew and fix the tenon connection area with a width of L in the double tenon area of ​​the double blade integrated preform along the thickness direction of the preform. Use continuous fiber bundles to sew and fix the edge tenon connection area along the thickness direction of the blade edge. After the sewing is completed, remove the sewing mold to obtain the double blade integrated preform.

[0018] A three-dimensional prefabricated body for a hot-end component is a single, integrally formed double-blade structure comprising two blades, two blade edges, two tenons, and a tenon connection area. The two blades, blade edges, and tenons respectively constitute two blades, connected by the tenon connection area, with each blade located at one end of the connection area. The fiber layer in the central area of ​​the prefabricated body has a length equal to the sum of the lengths of the two blades and the tenon connection area. This central fiber layer penetrates the entire prefabricated body, ensuring effective connection between the blades and tenons, and maintaining the symmetry and integrity of the double-blade structure. The fiber layer in the blade reinforcement area has a length equal to the sum of the lengths of a single blade, a single tenon, and the tenon connection area. The length of each layer varies depending on the tenon angle, ensuring continuity between the tenons and blades, effectively improving fiber strength utilization, and reserving space for intercalated fibers.

[0019] Furthermore, the fiber layer in the tenon joint area covers the two tenons and the tenon joint area, and the length of each layer is adjusted according to the size of the tenon and the requirements of the outer surface after the intercalated fiber is laid.

[0020] Furthermore, the two blades are placed into a composite molding mold to perform composite molding of the preform as a base. After the composite is completed, the tenon joint area is cut to obtain two blades.

[0021] Furthermore, the laid fiber cloth can be a high-performance fiber cloth such as carbon fiber cloth, silicon carbide cloth, quartz fiber cloth, or high-silica fiber cloth, and the continuous fiber bundle can be a high-performance fiber bundle such as carbon fiber, silicon carbide, alumina, high-silica, quartz, or aramid.

[0022] Furthermore, the stitching sequence is determined by the properties of the fiber cloth. To ensure the precise forming of the double-blade integrated preform, the stitching sequence of the double tenon area is adjusted according to whether the edge of the fiber cloth is loose. Loose fiber cloth can increase the local stitching of the tenon area, and then the tenon connection area is stitched to fix it.

[0023] Furthermore, for the one-piece preform of the double blades, before the blade area is sewn together, the blade area can be placed into a shaping mold, and the blade can be twisted and shaped before being sewn together along the twisted surface to fix the blade.

[0024] The application of the technical solution of the present invention has the following beneficial effects:

[0025] 1) The traditional manufacturing process of aero-engine blades is mostly done one by one, especially for fiber-reinforced blade components. According to product requirements, a single preform is first pre-formed and then the matrix is ​​composited. This invention adopts a double-blade integrated forming method, which forms a preform containing two blades in one step. After the matrix is ​​composited, it is cut apart to obtain two blade components. This is a rapid forming method for aero-engine blades. Moreover, the two blades are integrally formed in the same process, the manufacturing error is controllable, the product quality is highly stable, and it provides fast and reliable forming technology support for the development of aero-engines.

[0026] 2) The double-blade integrated preform proposed in this invention has high internal fiber continuity. From the perspective of a single blade, a certain proportion of through fiber layers are ensured in the blade body, blade root, and tenon area, which effectively improves the effective connection between the blade body and the tenon. At the same time, during the integrated molding process, due to the difference in size between the tenon and the blade body, the tenon part is designed to lay intercalated fibers along the axial direction, and the intercalated size covers both tenons, ensuring the consistency of the two tenon structures in the double-blade preform and ensuring the quality stability of the blade preform, providing technical support for mass production and rapid production.

[0027] 3) Based on the fact that blades include multiple structural features such as blade body, blade root, blade edge, and tenon, this invention adopts a partitioned design and partitioned forming method, which has a high degree of freedom in the forming process, a high degree of complexity in the forming process, and a strong designability of the blade structure obtained by manufacturing. The rapid blade forming method proposed in this invention can be applied to the blade manufacturing needs in a variety of scenarios. Attached Figure Description

[0028] The accompanying drawings are provided to further illustrate the invention and constitute a part of this invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0029] Figure 1 Schematic diagram of an aero-engine blade component

[0030] Figure 2 Schematic diagram of cross-section of a precast double-blade structure

[0031] Figure 3 Schematic diagram of single-sided aero-engine blade stitching

[0032] Figure 4 Diagram of a die for stitching blades of a dual-engine aircraft

[0033] Figure 5 Schematic diagram of a twin-blade aero-engine

[0034] 1-Central area, 2-Blade reinforcement area, 3-Blade edge connection area, 4-Edge tenon connection area, 5-Tenon insert area, 6-Seam line, 7-Upper mold module, 8-Connecting layer module, 9-Lower mold module Detailed Implementation

[0035] It should be noted that, unless otherwise specified, the embodiments and features of the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings:

[0036] (a) The thickness of the tenon of the aero-engine blade is 40mm. A three-dimensional CAD model of the tenon of the aero-engine blade is established and layered slicing is performed.

[0037] (b) Based on the three-dimensional CAD slice model and combined with the performance requirements of aero-engine blade components, 1K silicon carbide plain weave fabric with a thickness of 0.24mm was selected.

[0038] (c) Two aero-engine blade components are formed in a single process. The fiber layup layer of the double-blade preform can be divided into: blade center layer, blade reinforcement layer, blade edge connection layer, edge tenon connection layer and blade reinforcement area.

[0039] (d) Confirm that the length of the tenon connection area is 10mm. Further confirmation can be made that the size of the fiber cloth in the center layer of the blade is 120mm×50mm and the number of layers is 8; the size of the fiber cloth in the blade reinforcement layer is 115mm×50mm and the number of layers is 11; the size of the fiber cloth in the blade edge connection layer is 105mm×50mm and the number of layers is 8; the size of the fiber cloth in the edge tenon connection layer is 60mm×50mm and the number of layers is 9.

[0040] (e) Based on the angle of 45° and the radius of 5mm at the root of the aero-engine blade, the size of the fiber cloth in the insert area can be determined to be 16mm×60mm, and the number of inserts in each group is 3 pieces;

[0041] (f) Complete the layup and stitching of the leaf body center area, reinforcement area and leaf edge connection area in sequence, and then complete the insertion of the tenon area and the laying of the edge tenon connection area;

[0042] (g) Design and fabricate a stitching mold for the preform of aero-engine twin blades, such as Figure 4 The precast components that have been laid out are then installed onto the stitching mold;

[0043] (h) Since silicon carbide plain weave fabric is prone to losing silicon carbide fibers around its edges after being cut, the leaf root area should be sewn first.

[0044] (i) The tenon joint area is stitched, but the tenon itself is not stitched. Stitching the joint area ensures the consistency of the internal fiber structure and the stability of the tenon structure. Subsequent cutting does not affect the fiber utilization rate in the tenon area. The stitching thread used is 1K silicon carbide fiber. This completes the one-time forming of the twin-blade preform of the dual aero-engine. Figure 5 .

[0045] Finally, it should be noted that the above embodiments are further illustrative of the present invention and should not be construed as limiting the scope of the invention to the above embodiments. All technologies implemented based on the above content fall within the scope of the present invention.

Claims

1. A rapid prototyping method for a three-dimensional preform for a hot-end component, characterized in that, Includes the following steps: ①Based on the shape and performance requirements of the blades, a three-dimensional CAD model of the prefabricated body with two blades integrally formed was established, and the material specifications of the fiber cloth and fiber were determined; ② The three-dimensional CAD model of the double-blade integrated preform is partitioned to obtain the central area (1), blade reinforcement area (2), blade edge connection area (3), edge tenon connection area (4), and tenon insert area (5), and obtain data information such as the cross-sectional shape and thickness of different partitions; ③ The three-dimensional CAD models of the central area, blade reinforcement area, blade edge connection area, edge tenon connection area, and tenon insert area are sliced ​​layer by layer to obtain information such as the layer size and shape of the prefabricated body in different zones; ④ Based on the angle dimension β and radius R at the root of the double-blade prefabricated body, determine the specifications and quantity of the insert fiber cloth required for the tenon insert area, as well as the width L of the tenon connection area, and determine the number of lay-up layers, stitch spacing and stitch length for different zones; ⑤ Based on the size requirements of the double-blade integrated prefabricated body, determine the number of fiber cloth layers, and cut the specified fiber cloth according to the layer size and shape of the prefabricated body in different zones; ⑥ Position and lay the fiber cloth in the central area, the blade reinforcement area on both sides of the central area, and the blade edge connection area in sequence. Use the specified continuous fiber bundle to sew the fiber cloth layers of the blade area containing the central area, the blade reinforcement area, and the blade edge connection area to obtain the blade at one end of the integrated prefabricated body of the double blade. ⑦ Repeat step ⑥ to obtain the other end of the blade of the integrally formed preform of the double blades; ⑧ Number the pre-cut and prepared insert layer fiber cloth according to shape, specifications and quantity, and lay it in sequence with the already laid central area and leaf reinforcement area fiber until all insert fiber cloth is laid to obtain the tenon insert area. ⑨ After the fiber cloth for inserting the tenon is laid, place the fiber cloth for the tenon joint area on the upper and lower sides of the tenon insert area. Fix the two ends of the fiber cloth for the tenon joint area to the leaf edges of the double blades respectively, and wrap the tenon insert area. ⑩ Based on the structural characteristics of the double-blade tenon, an auxiliary sewing mold was designed and prepared to fix the two ends of the double blades on the sewing mold. The upper and lower modules of the sewing mold were locked, and the connecting layer module was used to fix the double tenon area of ​​the double-blade integral preform. ⑪ Using specified continuous fiber bundles, the tenon connection area with a width of L in the double tenon area of ​​the double blade integrated preform is sewn and fixed along the thickness direction of the preform. The edge tenon connection area is sewn and fixed along the thickness direction of the blade edge using specified continuous fiber bundles. After sewing is completed, the sewing mold is removed to obtain the double blade integrated preform.

2. A three-dimensional preform for a hot-end component, characterized in that, The prefabricated body is a single unit formed by two blades, including two blade bodies, two blade edges, two tenons and a tenon connection area; The two blades, two blade edges, and two tenons constitute two blades, which are connected by the tenon connection area. The two blades are located at one end of the tenon connection area respectively. The length of the fiber layer in the central area of ​​the prefabricated body is the sum of the lengths of the two blades and the length of the tenon connection area. The fiber layer in the central area runs through the entire prefabricated body, which on the one hand ensures the effective connection between the blade body and the tenon, and on the other hand ensures the symmetry and integrity of the double blade structure. The length of the fiber layer in the blade reinforcement area is the sum of the length of a single blade, a single tenon, and the tenon connection area. The length of each layer varies depending on the tenon angle, ensuring the continuity of the tenon and the blade, effectively improving the fiber strength utilization rate, and also reserving space for the intercalation of fibers.

3. The rapid prototyping method for blade preforms according to claim 1, characterized in that, The fiber layer in the tenon joint area covers the two tenons and the tenon joint area. The length of each layer is adjusted according to the size of the tenon and the requirements of the outer surface after the intercalated fiber is laid.

4. The rapid prototyping method for blade preforms according to claim 1, characterized in that, The two blades are placed into a composite molding mold to perform composite molding of the preform base. After the composite is completed, the tenon joint area is cut to obtain two blades.

5. The rapid prototyping method for blade preforms according to claim 1, characterized in that, The fiber cloth material can be one or more of carbon fiber cloth, silicon carbide fiber cloth, quartz fiber cloth, and high silica fiber cloth, and the continuous fiber bundle can be one or more of carbon fiber bundle, silicon carbide fiber bundle, high silica fiber bundle, quartz fiber bundle, aramid fiber bundle, and alumina fiber bundle.

6. The rapid prototyping method for blade preforms according to claim 1, characterized in that, The stitching sequence is determined by the properties of the fiber cloth. To ensure the accurate forming of the double-blade integrated preform, the stitching sequence of the double tenon area is adjusted according to whether the edge of the fiber cloth is loose. Loose fiber cloth can be stitched locally, and then the tenon connection area is stitched to fix it.

7. The rapid prototyping method for blade preforms according to claim 1, characterized in that, Before sewing the blade area of ​​the preformed double-blade integrated body, the blade area can be placed into a shaping mold, and the blade can be twisted and shaped before being sewn and fixed along the twisted surface.

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