A resin-based composite rotor blade considering meso-ply and a continuity modeling method and system thereof
Patent Information
- Application Number
- CN202610473032.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-10
- Publication Date
- 2026-08-07
AI Technical Summary
[0005]本发明的目的在于提供一种考虑细观铺层的树脂基复合材料转子叶片及其连续性建模方法、系统，能够解决复合材料风扇转子叶片模型铺层区域网格不连续的问题，提高复合材料风扇转子叶片计算模型的精度，且能规避现有的复合材料风扇转子叶片建模不连续的问题
1、本发明通过建立每层铺层在叶中面的投影轮廓，获得每个铺层的投影曲面，然后单独对每个铺层的投影面进行网格划分，形成了每个铺层边界清晰且不含锯齿的复合材料风扇转子叶片计算模型，解决了复合材料风扇转子叶片模型铺层区域网格不连续的问题，实现了叶片计算模型铺层轮廓与实际制造风扇转子叶片铺层轮廓的一致性，提高复合材料风扇转子叶片计算模型的精度；
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Figure CN122528376A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of rotor blade modeling and analysis technology, and discloses a method and system for modeling a resin-based composite rotor blade that considers micro-layouts and its continuity. Background Technology
[0002] Fiber-reinforced composite materials are widely used in aero-engines due to their advantages such as high specific strength, high specific stiffness, fatigue resistance, and strong design flexibility. Using fiber-reinforced composite blades can significantly reduce the blade's own mass, thereby reducing the mass of the containment system, bladed disk, and its transmission system, which is of great significance for improving engine efficiency. Research on the application of composite blades has gradually become a hot topic both domestically and internationally.
[0003] Compared to experimental research methods, numerical simulation can quickly and accurately obtain the stress distribution and strength reserve of blades under different operating conditions, and achieve iterative improvement results of blade structures more quickly, saving a significant amount of time and money. It plays an indispensable role in the forward design and preliminary research of blades. However, due to the complex structure of fiber-reinforced composite blades, especially fan rotor blades with numerous layups, modeling is difficult. Currently, most simulation models of composite blades use homogeneous materials, which cannot reflect the microstructural characteristics of composite blades. This not only affects the accuracy and results of the simulation but also makes it difficult to analyze the damage patterns of composite blades and establish a good mapping with experimental results.
[0004] While existing technologies have yielded some research results in establishing models of fiber-reinforced composite fan rotor blades, problems such as low modeling accuracy and model discontinuity still exist. In particular, the boundary lines of the layup regions in currently established composite fan rotor blade models are not smooth and continuous, but rather jagged mesh regions. This is because the smooth contour lines do not match the shape of the hexahedral mesh, causing the contour lines to wander along the mesh boundaries when dividing the layup regions. Consequently, the layup contour lines change from smooth curves to jagged broken lines, affecting modeling accuracy. Furthermore, due to the discontinuous size and shape of the layup regions and the presence of a certain thickness, the currently established composite fan rotor blade models form stepped boundaries between the layups when stacked into a solid structure, rather than smooth and continuous blade surfaces. This differs from actual blades and also affects the continuity of loads in subsequent simulations. The discontinuous mesh broken-line boundaries and the stepped boundaries of the blade solid reduce simulation accuracy, causing deviations between simulation and experimental results, and impacting the application prospects of composite fan rotor blades. Summary of the Invention
[0005] The purpose of this invention is to provide a method and system for modeling resin-based composite rotor blades and their continuity that considers micro-layouts. This method can solve the problem of mesh discontinuity in the layup region of composite fan rotor blade models, improve the accuracy of composite fan rotor blade calculation models, and avoid the problem of discontinuity in existing composite fan rotor blade modeling.
[0006] To achieve the above-mentioned technical effects, the technical solution adopted by the present invention is as follows:
[0007] A method for modeling the continuity of resin-based composite rotor blades considering mesoplaning includes: Based on the design 3D model of the homogeneous fan rotor blades, the blade base, blade back, and blade mid-surface of the fan rotor blades are extracted. Using the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back as the starting points, offset towards the leaf mid-surface according to the preset offset thickness to obtain the projected surface of each offset surface on the leaf mid-surface. The leaf back surface, leaf basin surface, and all projection surfaces are divided into grids according to the angle of each layer in the preset ply scheme, so that the grid angles of the leaf back surface, leaf basin surface, and each projection surface are consistent with the angles of the corresponding layers in the preset ply scheme. Using the mid-plane of the blade as a reference, the initial model of the resin-based composite fan rotor blade was simulated and stacked according to the stacking order in the preset layup scheme. The meshed back and blade basin surfaces are then applied to the initial blade model to obtain a composite material fan rotor blade computational model that is identical to the actual fan rotor blade structure.
[0008] Furthermore, the angle and stacking sequence of the blade layup are adjusted according to the strength design criteria to form the preset layup scheme of the resin-based composite fan rotor blade.
[0009] Furthermore, during the biasing process, the leaf basin surface and the leaf back surface pass through the leaf mid-surface.
[0010] Furthermore, the preset bias thickness is the actual layup thickness during the processing.
[0011] To achieve the above-mentioned technical effects, the present invention also provides a continuity modeling system for resin-based composite rotor blades considering mesophyll layers, used to implement the aforementioned continuity modeling method for resin-based composite rotor blades, comprising: The surface extraction module is used to extract the blade base, blade back, and blade mid-surface of the fan rotor blade based on the design 3D model of the homogeneous fan rotor blade; The projection surface generation module is used to take the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back surface as the starting points, and offset them to the leaf mid-surface according to the preset offset thickness to obtain the projection surface of each offset surface on the leaf mid-surface. The meshing module is used to mesh the back of the leaf, the leaf basin surface, and all projection surfaces according to the angle of each layer in the preset layup scheme, so that the mesh angle of the back of the leaf, the leaf basin surface, and each projection surface is consistent with the angle of the corresponding layer in the preset layup scheme. The initial model generation module is used to simulate and stack the initial model of the resin-based composite fan rotor blade according to the stacking order in the preset layup scheme, with the blade mid-surface as the reference. The computational model generation module is used to attach the meshed blade back and blade basin surfaces onto the initial blade model to obtain a computational model of a composite material fan rotor blade that is identical to the actual fan rotor blade structure.
[0012] Furthermore, in the initial model generation module, the angle and stacking order of the blade layup are adjusted according to the strength design criteria to form the preset layup scheme of the resin-based composite material fan rotor blade.
[0013] Furthermore, in the projection surface generation module, during the offset process, the leaf basin surface and the leaf back surface pass through the leaf mid-surface.
[0014] Furthermore, in the projection surface generation module, the preset offset thickness is the actual layup thickness during the processing.
[0015] To achieve the above-mentioned technical effects, the present invention also provides a resin-based composite rotor blade that considers micro-layouts, which is manufactured based on the computational model of the composite fan rotor blade.
[0016] Compared with the prior art, the beneficial effects of this invention are: 1. This invention obtains the projected contour of each ply on the blade mid-surface by establishing the projection contour of each ply, and then separately meshes the projection surface of each ply, forming a composite material fan rotor blade calculation model with clear boundaries and no serrations for each ply. This solves the problem of discontinuous mesh in the ply area of the composite material fan rotor blade model, realizes the consistency between the ply contour of the blade calculation model and the ply contour of the actual manufactured fan rotor blade, and improves the accuracy of the composite material fan rotor blade calculation model. 2. This invention attaches the blade basin surface and blade back surface to the initial model of the composite material fan rotor blade, so that the model has the same smooth blade profile and leading and trailing edges as the actual fan rotor blade, instead of a discontinuous stepped boss structure. This further avoids the problem of discontinuity in existing composite material fan rotor blade modeling and ensures that the simulation results match the experimental results. Attached Figure Description
[0017] Figure 1This is a flowchart of the method for modeling the continuity of resin-based composite rotor blades considering micro-layouts in Example 1 or 2; Figure 2 This is a schematic diagram of the leaf surface, leaf back, and leaf mid-surface in Example 2; Figure 3 This is a schematic diagram of a blade model with serrated boundaries in the prior art; Figure 4 This is a schematic diagram of the initial model of the composite material fan rotor blade with smooth boundaries in Example 2; Figure 5 This is a schematic diagram of the leaf-shaped surface of the discontinuous step structure in Example 2; Figure 6 This is a schematic diagram of the calculation model of the smooth blade profile and leading and trailing edge composite material fan rotor blade, which is the same as the actual fan rotor blade in Example 2. Detailed Implementation
[0018] The present invention will now be described in further detail with reference to the embodiments and accompanying drawings. However, this should not be construed as limiting the scope of the above-described subject matter of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.
[0019] Example 1 See Figure 1 A method for modeling the continuity of resin-based composite rotor blades considering mesophyll layers, comprising: Based on the design 3D model of the homogeneous fan rotor blades, the blade base, blade back, and blade mid-surface of the fan rotor blades are extracted. Using the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back as the starting points, offset towards the leaf mid-surface according to the preset offset thickness to obtain the projected surface of each offset surface on the leaf mid-surface. The leaf back surface, leaf basin surface, and all projection surfaces are divided into grids according to the angle of each layer in the preset ply scheme, so that the grid angles of the leaf back surface, leaf basin surface, and each projection surface are consistent with the angles of the corresponding layers in the preset ply scheme. Using the mid-plane of the blade as a reference, the initial model of the resin-based composite fan rotor blade was simulated and stacked according to the stacking order in the preset layup scheme. The meshed back and blade basin surfaces are then applied to the initial blade model to obtain a composite material fan rotor blade computational model that is identical to the actual fan rotor blade structure.
[0020] In this embodiment, by establishing the projected profile of each ply on the mid-surface of the blade, the projected surface of each ply is obtained. Then, the projected surface of each ply is individually meshed, forming a computational model of the composite fan rotor blade with clear boundaries and no serrations for each ply. This solves the problem of discontinuous mesh in the ply region of the composite fan rotor blade model and achieves consistency between the ply profile of the blade computational model and the ply profile of the actual manufactured fan rotor blade. Furthermore, by attaching the blade basin and blade back surface to the initial model of the composite fan rotor blade, the model possesses the same smooth blade profile and leading and trailing edges as the actual fan rotor blade, instead of a discontinuous stepped boss structure. The composite fan rotor blade model established by this method has higher accuracy than existing methods, more closely resembling the designed and manufactured actual composite fan rotor blade, and avoids the problem of discontinuity in existing composite fan rotor blade modeling, ensuring that the simulation results match the experimental results.
[0021] Based on the same inventive concept, this embodiment also provides a continuity modeling system for resin-based composite rotor blades considering mesophyll layers, used to implement the aforementioned continuity modeling method for resin-based composite rotor blades, including: The surface extraction module is used to extract the blade base, blade back, and blade mid-surface of the fan rotor blade based on the design 3D model of the homogeneous fan rotor blade; The projection surface generation module is used to take the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back surface as the starting points, and offset them to the leaf mid-surface according to the preset offset thickness to obtain the projection surface of each offset surface on the leaf mid-surface. The meshing module is used to mesh the back of the leaf, the leaf basin surface, and all projection surfaces according to the angle of each layer in the preset layup scheme, so that the mesh angle of the back of the leaf, the leaf basin surface, and each projection surface is consistent with the angle of the corresponding layer in the preset layup scheme. The initial model generation module is used to simulate and stack the initial model of the resin-based composite fan rotor blade according to the stacking order in the preset layup scheme, with the blade mid-surface as the reference. The computational model generation module is used to attach the meshed blade back and blade basin surfaces onto the initial blade model to obtain a computational model of a composite material fan rotor blade that is identical to the actual fan rotor blade structure.
[0022] Based on the same inventive concept, this embodiment also provides a resin-based composite rotor blade considering micro-layouts, which is manufactured based on the computational model of the composite fan rotor blade.
[0023] Example 2 See Figures 1 to 6This embodiment focuses on straight blades of a resin-based composite fan rotor. The blades employ a laminated structure, consisting of 154 unidirectional ply layers, each 0.1 mm thick. Fiber winding along the blade profile direction is defined as 0°, and fiber layup along the blade stacking axis is defined as 90°. Material parameters are shown in Table 1. The ply layers on the blade base and blade back are symmetrically distributed around the blade midplane, using a resin-based composite material with T300 reinforcing fibers.
[0024] Table 1 Material Parameter Table
[0025] The process of modeling the continuity of resin-based composite rotor blades in this embodiment is as follows: Step 1: Based on the design 3D model of the homogeneous fan rotor blades, extract the blade base, blade back, and blade mid-surface of the fan rotor blades; In this embodiment, the design three-dimensional model of the homogeneous fan rotor blade is imported into Ansa software. For the blade body of the design three-dimensional model, a cutting line is established with the center line of the front and rear edges of the blade as the boundary, and the blade basin surface and blade back surface segmented from the design three-dimensional model are extracted. Multiple leaf shape lines are extracted along the leaf height direction of the 3D design model. Then, the leaf mid-surface is established based on these leaf shape lines. The leaf base, leaf back, and leaf mid-surface are exported as igs format, such as... Figure 2 As shown.
[0026] Step 2: Using the leaf mid-surface as the modeling reference surface, and taking the leaf base and leaf back as the starting point, offset them to the leaf mid-surface according to the preset offset thickness to obtain the projected surface of each offset surface on the leaf mid-surface. Import the leaf basin, leaf back, and leaf middle surfaces in igs format into UG software. Starting from the leaf basin and leaf back surfaces, offset them towards the leaf middle surface. The offset distance is equal to the thickness of the selected layer type. Offset until the leaf basin and leaf back surfaces completely cross the leaf middle surface. During each offset process, the leaf base and leaf back surfaces are projected onto the leaf mid-surface to form the contour line of each offset surface on the leaf mid-surface, thus obtaining the corresponding projected surface. It is important to note that the portions of the leaf base and leaf back surfaces that cross the leaf mid-surface do not need to be projected.
[0027] Step 3: Divide the back of the leaf, the leaf basin, and all projection surfaces into a grid according to the angle of each layer in the preset layup scheme, so that the grid angle of the back of the leaf, the leaf basin, and each projection surface is consistent with the angle of the corresponding layer in the preset layup scheme. In this embodiment, the angle and stacking order of each ply are adjusted according to the strength design criteria to form the ply configuration of the resin-based composite fan rotor blade. The strength design criteria for blade ply configuration include, but are not limited to: no more than two plies with the same angle; ply sequence as symmetrical about the mid-plane as possible; and angle difference between adjacent plies not exceeding 45°. Then, the leaf mid-surface with the projected curved surface contour is imported into Ansa software. According to the angle of each ply in the preset ply scheme, the back surface of the leaf, the leaf basin surface, and all projected surfaces are divided into grids, so that the grid angles of the back surface of the leaf, the leaf basin surface, and each projected surface are consistent with the angles of the corresponding ply in the preset ply scheme, thus achieving consistency between the grid division area and the ply contour area.
[0028] Step 4: Using the mid-plane of the blade as a reference, simulate and stack the initial model of the resin-based composite fan rotor blade according to the stacking order in the preset layup scheme. In this embodiment, the blade mid-surface model with pre-grid mapping is imported into the ACP module of Workbench according to the stacking order in the preset layup scheme. Based on the blade mid-surface, the initial model of the resin-based composite fan rotor blade is stacked according to the layup scheme. Figure 3 It is currently the most common structure containing serrated boundary blade models. Figure 4 This is the initial model of a composite fan rotor blade with smooth boundaries after using this method.
[0029] Step 5: Apply the meshed back surface and blade basin surface to the initial blade model to obtain a composite material fan rotor blade calculation model with the same structure as the actual fan rotor blade. Because the ply profiles vary in size and the plies have thickness, the initial blade model obtained in step four is a discontinuous stepped structure with decreasing ply boundaries, rather than a smooth blade surface, as shown below. Figure 5 As shown. In this embodiment, the meshed back surface and leaf basin surface are laid on the initial leaf model, as shown. Figure 6 As shown, the computational model of the composite material fan rotor blade has the same smooth blade surface and leading and trailing edges as the actual fan rotor blade, instead of a discontinuous stepped boss structure.
[0030] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A method for modeling the continuity of resin-based composite rotor blades considering mesophyll layers, characterized in that, include: Based on the design 3D model of the homogeneous fan rotor blades, the blade base, blade back, and blade mid-surface of the fan rotor blades are extracted. Using the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back as the starting points, offset towards the leaf mid-surface according to the preset offset thickness to obtain the projected surface of each offset surface on the leaf mid-surface. The leaf back surface, leaf basin surface, and all projection surfaces are divided into grids according to the angle of each layer in the preset ply scheme, so that the grid angles of the leaf back surface, leaf basin surface, and each projection surface are consistent with the angles of the corresponding layers in the preset ply scheme. Using the mid-plane of the blade as a reference, the initial model of the resin-based composite fan rotor blade was simulated and stacked according to the stacking order in the preset layup scheme. The meshed back and blade basin surfaces are then applied to the initial blade model to obtain a composite material fan rotor blade computational model that is identical to the actual fan rotor blade structure.
2. The method for continuous modeling of resin-based composite rotor blades according to claim 1, characterized in that, The preset layup scheme of the resin-based composite fan rotor blade is formed by adjusting the blade layup angle and stacking sequence according to the strength design criteria.
3. The method for continuous modeling of resin-based composite rotor blades according to claim 1, characterized in that, During the offset process, the leaf basin surface and leaf back surface pass through the leaf mid-surface.
4. The method for continuous modeling of resin-based composite rotor blades according to claim 1, characterized in that, The preset offset thickness is the actual layup thickness during the processing.
5. A continuity modeling system for resin-based composite rotor blades considering mesophyll layers, used to implement the continuity modeling method for resin-based composite rotor blades as described in claim 1, characterized in that, include: The surface extraction module is used to extract the blade base, blade back, and blade mid-surface of the fan rotor blade based on the design 3D model of the homogeneous fan rotor blade; The projection surface generation module is used to take the leaf mid-surface as the modeling reference surface, and the leaf base and leaf back surface as the starting points, and offset them to the leaf mid-surface according to the preset offset thickness to obtain the projection surface of each offset surface on the leaf mid-surface. The meshing module is used to mesh the back of the leaf, the leaf basin surface, and all projection surfaces according to the angle of each layer in the preset layup scheme, so that the mesh angle of the back of the leaf, the leaf basin surface, and each projection surface is consistent with the angle of the corresponding layer in the preset layup scheme. The initial model generation module is used to simulate and stack the initial model of the resin-based composite fan rotor blade according to the stacking order in the preset layup scheme, with the blade mid-surface as the reference. The computational model generation module is used to attach the meshed blade back and blade basin surfaces onto the initial blade model to obtain a computational model of a composite material fan rotor blade that is identical to the actual fan rotor blade structure.
6. The resin-based composite material rotor blade continuity modeling system according to claim 5, characterized in that, In the initial model generation module, the angle and stacking order of the blade layup are adjusted according to the strength design criteria to form the preset layup scheme of the resin-based composite material fan rotor blade.
7. The resin-based composite rotor blade continuity modeling system according to claim 5, characterized in that, In the projection surface generation module, during the offset process, the leaf basin surface and the leaf back surface pass through the leaf mid-surface.
8. The resin-based composite material rotor blade continuity modeling system according to claim 5, characterized in that, In the projection surface generation module, the preset offset thickness is the actual layup thickness during the processing.
9. A resin-based composite rotor blade considering micro-layouts, characterized in that, The composite material fan rotor blades were manufactured based on the computational model described in any one of claims 1-4.