Method for determining a weaving map

Abstract

One aspect of the invention relates to a method for determining a weaving map of a zone of a part to be manufactured in a woven composite material, comprising: - receiving a representation of said zone of the part; - receiving predefined values of parameters relating to manufacturing constraints in the zone of the part; - determining, from the representation and from a first subset of values from among the received predefined values, a weaving grid of the zone of the part, the weaving grid comprising a plurality of cells; and - successively determining, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values from among the received predefined values.

Description

DESCRIPTION TITLE: METHOD FOR DETERMINING A WEAVE MAP TECHNICAL FIELD OF THE INVENTION

[0001] The technical field of the invention is that of parts made from a woven composite material, in particular aeronautical parts such as aircraft engine blades.

[0002] In particular, the invention relates to the design of a woven reinforcement of a part by producing a weaving map representing the weaving structure of the reinforcement before its manufacture. TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0003] A woven composite material is an assembly comprising at least one woven textile framework called reinforcement and a binder called matrix. The reinforcement comprises strands (also called "threads") woven using a loom, following a theoretical weaving topology defined according to at least two orientations, also called reinforcing axes, each strand comprising a plurality of fibers, often carbon or glass. The reinforcing axes are conventionally called "warp" and "weft". In general, the warp corresponds to the main weaving direction, and the weft corresponds to the transverse direction, orthogonal to the warp. The way in which the strands are interwoven (i.e. the pattern in which the strands are woven) is conventionally called "weave".

[0004] An example of such a woven composite material is shown in Figure 1. In Figure 1, the reinforcement of the woven composite material 100 comprises strands 101, 102 woven according to a weaving topology defined on several layers 103a, 103b, the strands being arranged according to two orthogonal reinforcement axes X and Y, respectively called warp and weft, the layers 103a, 103b being superimposed along the Z axis.

[0005] The manufacture of a part in a woven composite material therefore requires a first stage of manufacturing (or "making") of the reinforcement by weaving, then a second stage of assembly with the matrix, for example by injection after shaping in a mold. At the end of the first stage of manufacturing the reinforcement by weaving, we obtain a woven reinforcement also called a "preform".

[0006] For example, in the resin transfer molding process, the preform is placed in a rigid mold, with the preform conforming to the shape of the mold. A liquid or viscous resin is then injected into the mold containing the preform using a low-pressure pump.

[0007] The design of woven reinforcement, i.e. the preform, is a complex process, which requires in-depth knowledge of the material properties derived from the structure and type of reinforcement, as well as the manufacturing processes. Indeed, the composite material must have certain mechanical characteristics, which are set by the design office depending on the type of part, while its manufacturing process is subject to various constraints.

[0008] Thus, the design of the woven reinforcement requires significant upstream work during which an optimal compromise must be found between the requirements relating to material characteristics and the constraints imposed by weaving. There are software programs incorporating textile layer optimization algorithms, but these programs do not take into account the constraints imposed by weaving or the optimization of the armors. Thus, the programming of a textile part requires a significant amount of time (of the order of several months for a complex part) which has a major impact on the iterations between the design office and the textile workshop and, consequently, on product development times.

[0009] The invention improves the situation. SUMMARY OF THE INVENTION

[0010] The invention offers a solution to the problems mentioned above, by making it possible to automatically and quickly design the architecture of the woven reinforcement according to a set of manufacturing constraints.

[0011] One aspect of the invention thus relates to a computer-implemented method for determining a weaving map of an area of ​​a part to be manufactured from a woven composite material. The method may comprise: receiving a representation of said area of ​​the part; receiving predefined values ​​of parameters relating to manufacturing constraints of the area of ​​the part; determining, from the representation of the area of ​​the part and a first subset of values ​​among the predefined values ​​received, a weaving grid of the area of ​​the part, the weaving grid comprising a plurality of cells; and successively determining, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​among the predefined values ​​received; wherein the determination of a weaving composition for a current cell of the weaving grid depends on a weaving composition already determined for a cell of the weaving grid adjacent to the current cell; and wherein the weaving mapping of the area of ​​the part comprises the cells of the weaving grid and the respective weaving compositions.

[0012] By "weave mapping" is meant a set of data making it possible to represent a weave associated with an area of ​​a mechanical part (for example, a woven reinforcement). By "weave composition" is meant a set of data making it possible to characterize the weave in the area concerned, in particular the type of yarns used and the way in which the yarns are arranged relative to each other. In other words, the weave composition makes it possible to completely define the weave within a cell, and the weave mapping corresponds to the set of weave compositions for the cells. Thus, the weave mapping makes it possible to represent the weave architecture of the area of ​​the mechanical part.

[0013] By "zone" is meant a region of a mechanical part to be manufactured from a woven material. A mechanical part to be manufactured may comprise a plurality of zones. By extension, the term "zone" may also refer to an entire mechanical part (for example, of small size, and for which the manufacturing constraints are the same at every point of the part).

[0014] Parameters related to manufacturing constraints of the area are parameters representing criteria to be respected for the design of the weave, which are typically determined or validated upstream by experts. The values ​​of these parameters depend on the type of part to be manufactured, and even on the area of ​​the part to be manufactured. In other words, for two different areas of the same part (e.g. example the root and tip of an engine blade), the parameter values ​​may differ.

[0015] By "weaving grid" is meant a mesh of the area of ​​the part considered. The determination of the weaving grid therefore includes the determination of this mesh, and in particular of the dimensions of the cells. This determination is advantageously carried out from a first subset of values ​​among the predefined values ​​of the parameters relating to the manufacturing constraints received.

[0016] By "weaving composition" is meant a set of parameters allowing the weaving to be characterized (number of warp and weft threads, relative arrangements of the threads with respect to each other, number of layers, etc.). For each cell of the weaving grid, the weaving composition is determined using a second subset of values ​​from among the predefined values ​​of the parameters relating to the received manufacturing constraints. Thus, the determined composition advantageously takes into account the manufacturing constraints imposed for the part.

[0017] By "current cell" is meant a cell for which the weaving composition is determined (i.e. the cell considered at a current step of the process), as opposed to cells for which the compositions have already been determined and to cells for which the determination of the weaving composition is done at steps subsequent to the current step. By "adjacent cell" (or neighboring cell) is meant a cell belonging to a predefined neighborhood of the cell in the weaving grid, for example a neighborhood of 4-connectivity.

[0018] The above method proposes to determine, in successive steps, a respective weave composition for each cell of the weaving grid. In other words, once the weave composition has been determined for a cell, the weave composition is determined for another cell, and so on until all the cells of the grid have been covered. By "weave composition already determined for a cell", we therefore mean a weave composition determined for a cell different from the current cell during a step prior to the current step.

[0019] According to this method, the weave composition of a cell advantageously takes into account the weave compositions already determined for neighboring cells, thus avoiding structural problems in the weave composition (for example, incompatible weave compositions between adjacent cells).

[0020] In one or more embodiments, the representation of the part area may include at least one two-dimensional model of the part area. For example, the at least one two-dimensional model of the part may include at least one thickness map of the part area.

[0021] By "part area thickness mapping" is meant a set of data making it possible to characterize a contour of a section of the part along a plane (X,Y) for example, and thicknesses along the Z axis within this contour. For example, a thickness mapping may be presented in the form of an image showing a contour, and in which each pixel within the contour is associated with a value which depends on the thickness of the part at this pixel.

[0022] In one or more embodiments, the method further comprises: receiving an initial cell from among the plurality of cells of the weaving grid; wherein the successive determination, for each cell of the weaving grid, of the respective weaving composition is performed according to a traversal order of the cells of the weaving grid having a starting point corresponding to the initial cell, the traversal order of the cells being such that each current cell other than the initial cell for which the weaving composition is determined is adjacent to another cell of the weaving grid for which the weaving composition has already been determined.

[0023] In other words, it is ensured, thanks to such a traversal order, that the weaving compositions of the cells are determined from the weaving compositions already determined for the neighboring cells.

[0024] In one or more embodiments, determining the weave composition for the current cell of the weave grid depends on any weave compositions already determined for cells of the weave grid adjacent to the current cell.

[0025] In one or more embodiments, the first subset of the received predefined values ​​may include a list of allowed weaves, a list of allowed weft counts, a list of allowed warp counts, and one or more target warp spacing values.Determining the weave pattern of the area of ​​the piece may include: selecting a weave for the area from the list of permitted weaves; selecting a weft count for the area from the list of permitted weft counts; selecting a warp count for the area from the list of permitted warp counts; determining a warp spacing value from the one or more target warp spacing values ​​and the selected warp count; and determining a weft spacing for the area based on the selected warp count, the selected weft count, and the determined target warp spacing value.

[0026] In one or more embodiments, the respective weave composition may comprise a set of parameters representative of a number of weft yarns and warp yarns and a relative arrangement of the weft yarns and warp yarns in said each cell of the weave grid.

[0027] For example, for each cell of the weaving grid, determining the respective weave composition may include: associating with said each cell a respective vector, and assigning to each component of the vector a value indicating a presence or absence of a yarn at a position corresponding to said component in the cell, and an associated yarn type. The yarn type may be one of: a warp yarn and a weft yarn.

[0028] In one or more embodiments, the representation of said received part area may include thickness data representing thicknesses of the part area at a plurality of points in the part area, and determining the weave composition for a current cell of the weave grid may include: determining a number of weave layers in the cell current as a function of a thickness data representing a thickness at a point in the area of ​​the part corresponding to the current cell and as a function of at least one number of weaving layers already determined for at least one respective cell of the weaving grid adjacent to the current cell.

[0029] Thus, the number of layers of a cell is advantageously determined by taking into account the number of layers of neighboring cells for which the weaving composition has already been determined.

[0030] In one or more embodiments, the second subset of parameters relating to manufacturing constraints of the area of ​​the part may include a target fiber volume fraction value and a target warp-to-weft ratio value. The weave composition of a cell of the weave grid may be determined to jointly minimize a deviation between a fiber volume fraction value in the cell and the target fiber volume fraction value and a deviation between a warp-to-weft ratio value in the cell and the target warp-to-weft ratio value.

[0031] Alternatively, the second subset of parameters relating to manufacturing constraints of the part area may include a range of target fiber volume fraction values ​​and a range of target warp-to-weft ratio values. The weave composition of a cell of the weave grid may be determined such that a fiber volume fraction value in the cell falls within the range of target fiber volume fraction values ​​and a warp-to-weft ratio value in the cell falls within the range of target warp-to-weft ratio values.

[0032] A combination of these embodiments is of course possible (minimizing the difference between the obtained value and the target value for one of the parameters, and determining the value so that it belongs to the target value range for the other parameter).

[0033] Another aspect of the invention relates to a computer-implemented method of determining a weave map of a part to be manufactured from a woven composite material. The method may comprise: receiving a plurality of zones of the part to be manufactured, wherein each zone comprises at least one portion adjacent to a portion of another zone; for each zone among the plurality of zones, successively determining weave maps of said each zone by the above method; wherein the determination of the weave map of a current zone is a function of the weave map of a zone other than the current zone for which the respective weave map has been determined, the current zone comprising a portion adjacent to a portion of the other zone.

[0034] In these embodiments, determining the weave mapping for the current area may include: identifying a cell of the current area adjacent to at least one cell of the other area for which the respective weave mapping has been determined; and determining the weave composition for the identified cell from the at least one weave composition determined for the at least one adjacent cell of the respective other area.

[0035] Thus, adjacent areas for which weave maps have already been determined are advantageously taken into account for determining the weave map of a current area.

[0036] The plurality of zones may comprise groups of zones, each group of zones being respectively associated with a layer of the part to be manufactured.

[0037] In one or more embodiments, the part to be manufactured may be an aeronautical part.

[0038] Another aspect of the invention relates to a method of manufacturing a part in a woven composite material which may comprise: determining a weave map of the part according to one of the above methods; manufacture the part from the determined part weaving map.

[0039] Another aspect of the invention relates to a device for determining a weaving map of an area of ​​a part to be manufactured in a woven composite material. The device may comprise: an input interface for receiving a representation of said area of ​​the part and predefined values ​​of parameters relating to manufacturing constraints of the area of ​​the part; at least one circuit for: determining, from the representation of the area of ​​the part and a first subset of values ​​among the predefined values ​​received, a weaving grid of the area of ​​the part, the weaving grid comprising a plurality of cells; and successively determining, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​among the predefined values ​​received;wherein the determination of the weave composition for a current cell of the weave grid depends on a weave composition already determined for a cell of the weave grid adjacent to the current cell; and wherein the weave mapping of the area of ​​the part comprises the cells of the weave grid and the respective weave compositions.;

[0040] Another aspect of the invention relates to a system for determining a weave map of a part to be manufactured in a woven composite material, the part to be manufactured comprising a plurality of zones, wherein each zone comprises at least one portion adjacent to a portion of another zone, the system comprising a plurality of preceding devices, each device being configured to determine a weave map of a respective zone among the plurality of zones; wherein the determination of the weave map of a current zone is a function of the weave map of another zone than the zone current area for which the respective weave mapping has been determined, the current area comprising a portion adjacent to a portion of the other area.

[0041] The invention also relates to a system for manufacturing a part in a woven composite material, which may comprise: a system for determining a weave map of the part as previously; and a loom for manufacturing the part from the determined weave map of the part.

[0042] A computer program, implementing all or part of the process described above, installed on pre-existing equipment, is in itself advantageous.

[0043] Thus, the present invention also relates to a computer program product comprising instructions for implementing certain steps of the methods previously described, when this program is executed by a processor.

[0044] This program may use any programming language (e.g., an object-oriented language or otherwise), and may be in the form of interpretable source code, partially compiled code, or fully compiled code.

[0045] Figure 2 described in detail below can form the flowchart of the general algorithm of such a computer program.

[0046] The invention and its various applications will be better understood by reading the following description and examining the accompanying figures. BRIEF DESCRIPTION OF THE FIGURES

[0047] Other features and advantages of the invention will become apparent upon reading the description, which may be read in conjunction with the figures. These figures are presented for information purposes only and in no way limit the invention.

[0048] Figure 1 shows an example of a woven composite material.

[0049] Figure 2 represents a flowchart of a method for determining a weave map for a part to be manufactured in a woven composite material, according to one embodiment.

[0050] Figure 3a shows an example of regions of a part to be manufactured in a woven composite material.

[0051] Figure 3b shows an example of layers of a part to be manufactured in a woven composite material.

[0052] Figure 4 shows several sections of a weaving grid of a portion of a part to be manufactured in a woven composite material, according to one embodiment.

[0053] Figure 5 represents an order of traversal of the weaving grid, according to one embodiment.

[0054] Figure 6 represents a device configured to implement steps of the method for determining a weaving map for a part to be manufactured in a woven composite material, according to one embodiment.

[0055] Figure 7 represents an example of a method for determining the weaving composition of an initial cell according to one embodiment. DETAILED DESCRIPTION

[0056] Figure 2 represents a flowchart of a method for determining a weave map for a part to be manufactured in a woven composite material, according to one or more embodiments.

[0057] By "weaving mapping" is meant a spatial representation of the structure (i.e. the different types of yarns used and the way in which they are entangled) of the reinforcement of the part to be manufactured, this mapping can subsequently be used to weave said reinforcement according to the determined structure. By extension, the term "weaving mapping" also designates a set of data characterizing or making it possible to obtain the spatial representation of the structure of the woven reinforcement.

[0058] In a first step 210, a model of the part to be manufactured may be received. The model of the part to be manufactured may include in particular a 2D representation of the part, as well as different areas of the part. The 2D representation may be, for example, a 2D thickness map, i.e. a 2D model representing an outline of the part (typically the outline of a 2D projection of the part onto a plane (X,Y)) and, for each point inside the contour, a thickness datum of the part at this point in a third direction (for example Z). The model received in step 210 may further comprise data relating to different areas of the part, the different areas of the part corresponding to regions of the part whose weaving properties or constraints differ from each other.

[0059] An example of such regions is shown in Figure 3a. In the example of Figure 3a, the part to be manufactured is an aircraft engine blade, and four zones 301 a, 301 b, 301 c, 301 d of the part are predefined. In this example, the zones 301 a, 301 b, 301 c, 301 d correspond to four regions subdividing the blade in its longitudinal axis. Of course, depending on the embodiments, the number of zones may be other than four (for example one, two, three, five or more than five), and the zones may be defined along other axes, or even along no preferred axis (the zones constituting any mapping of the part). In the example of Figure 3a, the zones 301 a, 301 b, 301 c, 301 d represent regions of the part for which the desired mechanical properties and weaving constraints are not necessarily the same from one region to another.In contrast, the desired mechanical properties and weaving constraints do not vary within a predefined area.

[0060] Furthermore, in one or more embodiments, the model of the part to be manufactured received during step 210 of Figure 2 may comprise a plurality of “layers”, i.e. a set of layers some of which are superimposed (partially or completely), generally defined by an expert and intended to be used in computer-aided design software. An example of layers is shown in Figure 3b.

[0061] In the example of Figure 3b, the model of the object comprises a plurality of layers 302a, 302b, 302c, 302d, 302e, 302f, represented on the left diagram in a (X,Y) frame and on the right diagram in a (Y,Z) frame. Each layer may itself be composed of one or more zones as defined previously with reference to Figure 3a. Thus, in certain embodiments, the model of the part received in step 210 of Figure 2 may comprise a plurality of 2D representations respectively associated with the different layers and the different zones. For example, a 2D thickness map may be received for each layer, the thickness mapping showing the geometry (i.e. the contours), as well as data to characterize the different zones of the layer. Of course, the number of layers is not fixed at six as in the example of Figure 3b. Depending on the embodiments, there may be a single layer, or any (integer) number of layers, or even no layers strictly speaking (the part is then represented by a 2D model comprising one or more zones).

[0062] Referring again to Figure 2, in one or more embodiments, the coordinates of a reference point, also called “piece zero,” may be received during step 210. Advantageously, this reference point belongs to a single zone as defined previously, and to a single layer if the model comprises a plurality of layers. As detailed later, this reference point constitutes the starting point for determining the weaving composition in the different cells of the model (also called “population” of the cells). The coordinates of the piece zero are conventionally set at (0,0,0) in the three-dimensional orthogonal reference frame (X,Y,Z).

[0063] In a step 220, a set of predefined values ​​of parameters relating to manufacturing constraints is received. These are predetermined values, which correspond to target values ​​(i.e. values ​​that are desired to be achieved by means of the process) or imposed values ​​(for example by the loom or by constraints linked to the part to be manufactured known by the experts in the field). These predetermined values ​​are conventionally set by an expert as well as by the technical specifications, but also by the constraints of the loom for example. The parameters relating to manufacturing constraints may be related to mechanical characteristics desired for the part (necessary so that the part can be certified and used subsequently), and may therefore be related to the yarns used and / or to the way in which the yarns are arranged, such as the warp-to-weft ratio or the fiber volume fraction.It is recalled that the warp-weft ratio (WTR) corresponds to the ratio between the surface mass of the warp yarn and the surface mass of the weft yarn, and that the fiber volume fraction (FV) corresponds to the percentage of fibers in a volume of the composite material (reinforcement and matrix).

[0064] The predefined values ​​may be associated with a specific area of ​​the model received at step 210. Thus, at step 220, multiple sets of values ​​may be received, each set being associated with a respective area.

[0065] For example, continuing with the example of Figure 3a, respective sets of RCT and FV values ​​may be received at step 220 for areas 301a (blade root), 301b (lower middle portion), 301c (upper middle portion), and 301d (blade tip). For each area 301a, 301b, 301c, 301d, the RCT and / or FV value may be one or more point values, or a range of values.

[0066] Parameters relating to manufacturing constraints can also be directly linked to the weaving method used. Indeed, the weaving of certain reinforcements may be subject to limitations in terms of weaving, either due to the part itself (for example, due to its geometry and its future use - for example, a blade and an engine retention casing are not made using the same weaving method), or due to the loom used (which may, for example, not allow the use of all armors or all types of yarn).Thus, the predefined values ​​of the parameters received in step 220 may also include, in a non-limiting manner, one or more values ​​from among: one or more authorized weaves, a target weft spacing value (or range of values), a target warp spacing value (or range of values), one or more possible weft yarn counts, one or more possible warp yarn counts, a maximum number of textile layers, a minimum number of textile layers, a minimum number of warps and a minimum number of wefts, a maximum number of warps and a maximum number of wefts.

[0067] It is recalled that the weave corresponds to the assembly pattern of the threads (interlacing pattern of warps and wefts). The weft (resp. warp) spacing corresponds to the distance between two successive weft (resp. warp) threads. The yarn “count” corresponds to the type of thread, characterized by its linear mass, which depends in particular on the number of fibers that compose it. For example, the available yarn counts can be 12k, 24k, 36k, 48k, 72k, etc., where a count “Xk” corresponds to a thread comprising Xx1000 fibers per thread. The list of available yarn counts may differ between the warp and the weft. The maximum (resp. minimum) number of textile layers corresponds to the maximum (resp. minimum) number of textile layers that a warp thread can (resp.must) cross through the thickness - this technique is used in 3D weaving, allowing interlacing between the different layers, thus eliminating interfaces within the reinforcement and consequently improving its mechanical properties. Finally, the maximum (resp. minimum) number of warps (resp. wefts). represents the maximum (resp. minimum) number of warp (resp. weft) threads in a warp / weft plane (X,Y).

[0068] A weaving grid is then determined at a step 230. In one or more embodiments, the weaving grid may comprise a plurality of grids, herein referred to as 2D “intermediate weaving grids”, each intermediate weaving grid being, for example, respectively associated with a layer among the plurality of layers received, if any, at step 210 and / or with a zone among the plurality of zones received, if any, at step 210. When the model comprises only one layer (or no layers) and only one zone, there may be only one intermediate grid, which constitutes the weaving grid.

[0069] Each intermediate weaving grid may comprise a plurality of cells, for example nx * ny cells distributed along the warp and weft axes (X,Y). Each cell of an intermediate weaving grid may be associated with a thickness value, which represents a thickness of the cell in a third direction Z. The thickness values ​​of the cells are variables, which are part of the parameter values ​​that the described method proposes to determine.

[0070] During step 230, the intermediate weaving grids are determined for all the layers and / or all the zones of the part, from the representation received in step 210 and the predefined values ​​of parameters relating to manufacturing constraints received in step 220. For a zone of a layer for example, the associated weaving grid can represent a mesh of said zone of the layer, in which each cell of the mesh can be associated with a thickness value of the cell, as well as with a number of textile layers in the cell.

[0071] According to one embodiment, step 230 may comprise a first step of determining the weaving composition associated with a so-called “initial” cell, which corresponds to the zero piece. Thus, when the model received in step 210 comprises several zones / layers, the determination 230 of the intermediate weaving grids respectively associated with these zones / layers begins with the determination of the intermediate weaving grid associated with the zone / layer comprising the zero piece, and with a first step of determining the weaving composition of the cell associated with the zero piece. Once the intermediate weaving grid associated with the layer / zone comprising the zero piece is determined, the other intermediate weaving grids can in turn be determined according to an order explained below.

[0072] During this first step of determining the weaving composition of the initial cell, one or more combinations of values ​​are determined for the following parameters: weave, counts of the weft and warp yarns, warp spacing and weft spacing. A number of layers is also determined for the initial cell. These combinations of values ​​are determined so as to be compatible with the weaving constraints, i.e. with the values ​​of the parameters relating to manufacturing constraints received in step 220.

[0073] There may be several combinations of weaving parameter values ​​compatible with the values ​​of the parameters relating to manufacturing constraints received in step 220. In this case, the user may be required to choose one or more combinations from among the compatible combinations to continue the method of Figure 2.

[0074] In one or more embodiments, this first step of determining the weave composition of the initial cell may also include determining a number of layers in the initial cell (i.e. corresponding to piece zero) and determining a thickness of the initial cell. For example, the thickness of the initial cell may be determined from a weft spacing among possible weft spacing values ​​and the thickness of the piece, provided as input with the model of the piece during step 210 (typically the value indicated by the thickness mapping at the point corresponding to piece zero). The number of layers may be determined from a warp yarn count among the list of possible warp yarn counts, a weft yarn count among the list of possible weft yarn counts, a thickness of the cell and a target fiber volume fraction.

[0075] An example of implementation of this first step of determining the weaving composition of the initial cell according to one embodiment is shown in Figure 7.

[0076] The inputs to this first determination step are: list of possible warp yarn counts, list of possible weft yarn counts, a warp spacing, a target volume fraction, a target warp-weft ratio, a number of minimum layers and a maximum number of layers for the cell, and a minimum frame spacing and a maximum frame spacing for the cell.

[0077] In a first series of steps 710, a weft spacing and a number of layers in the initial cell are determined, for each possible combination {warp yarn; weft yarn} among the list of possible warp yarn counts and the list of possible weft yarn counts. For example, if the list of possible warp yarn counts includes 3 yarn counts and the list of possible weft yarn counts includes 2 yarn counts, the weft spacing and the number of layers are determined for the 3x2 = 6 possible combinations. The series of steps 710, as well as the series of steps 720 and the final test 730, are therefore implemented for the 6 possible combinations.

[0078] For each combination {warp yarn; weft yarn} among the set of possible combinations, an initial weft spacing is calculated in a step 711. This initial weft spacing can be calculated as a function of the warp spacing and the target warp-weft ratio:

[0079] FLinit = fFi_(string spacing, target RCT).

[0080] Then, a thickness of the cell can be determined in a step 712 as a function of the initial raster spacing calculated in step 711:

[0081] t = ft(FLinit).

[0082] An initial number of layers can then be determined in a step 713, from the warp yarn count, the weft yarn count, the initial weft spacing (determined in step 711), the target volume fraction (VF) and the thickness (determined in step 712):

[0083] NBinit = fNB(warp thread, weft thread, FLinit, target FV, t).

[0084] The weft spacing value can then be updated in step 714 from the warp yarn count, the weft yarn count, the initial number of layers determined in step 713, the target FV and the thickness determined in step 712:

[0085] FL = fFi_(warp thread, weft thread, NBinit, target FV, t).

[0086] Finally, the number of layers of the cell can be updated during a step 715, depending on the warp yarn count, the weft yarn count, the spacing of frame updated in step 714, of the target FV and of the thickness determined in step 712:

[0087] NB = fNB(warp yarn, weft yarn, FL, target FV, t).

[0088] Once the raster spacing and the number of layers in the initial cell have been determined in the series of steps 710 (comprising steps 711 to 715), a test can be performed in step 720 on the number of layers determined in step 715. If the number of layers obtained in step 715 is different from the initial number of layers determined in step 713, a new series of steps 720 can be implemented to optimize the number of layers and stabilize this number of layers according to the variations in the raster spacing and the thickness. If the number of layers obtained in step 715 is equal to the initial number of layers determined in step 713, the series of steps 740 can be directly implemented.

[0089] When implemented, the series of steps 730 may include a step 731 of updating the frame spacing, a step 732 of updating the cell thickness, an update 733 of the number of layers and a test 734 of stability on the number of layers.

[0090] The weft spacing may be updated in step 731 based on the warp yarn count, the weft yarn count, the number of layers determined in step 715, the target FV, and the cell thickness determined in step 712:

[0091] FL = fFi_(warp yarn, weft yarn, NB, target FV, t).

[0092] Then, the cell thickness can be updated in step 732 based on the raster spacing calculated in step 731:

[0093] t = ft(FLinit).

[0094] The number of layers can then be updated in step 733 based on the warp yarn count, weft yarn count, weft spacing updated in step 731, target FV, and thickness updated in step 732:

[0095] NB = fNB(warp yarn, weft yarn, FL, target FV, t).

[0096] Finally, a stability test 734 on the number of layers is implemented, in which it is checked whether the number of layers updated at a step 733 is sufficiently close to the number of layers calculated at step 733 of the previous iteration of the series of steps 730 (or the number of layers calculated at step 715 if it is the first iteration of the series of steps 730). In other words, the test 734 corresponds to a convergence test of the calculated number of layers. A convergence criterion may be, for example, a difference between the current value of the number of layers and the previous value of the number of layers less than a predetermined threshold, and / or a difference between the current value of the number of layers and the minimum number of layers less than a predetermined value (in other words, with this last criterion, it is checked whether the minimum number of layers is reached).

[0097] If the convergence criterion is not met (test 734, “ko” arrow), a new iteration of the series of steps 730 is implemented. If the convergence criterion is met (test 734, “ok” arrow), the series of steps 740 is implemented.

[0098] The series of steps 740 includes a final test 741 at the end of which it is determined whether the calculated set of values ​​is retained as a possible solution (743) or whether it is excluded from the possible solutions (742).

[0099] In test 741, two cumulative conditions can be verified:

[0100] Condition 1: The frame spacing obtained at the end of the series of steps 730 when it is implemented, or at the end of the series of steps 710 when the series of steps 730 is not implemented, must be between the minimum frame spacing and the maximum frame spacing; and

[0101] Condition 2: The number of layers obtained at the end of the series of steps 730 when it is implemented, or at the end of the series of steps 710 when the series of steps 730 is not implemented, must be less than or equal to the maximum number of layers.

[0102] If at least one of the two conditions is not satisfied, the calculated set of values ​​(i.e. the combination {warp yarn count, weft yarn count, weft spacing, number of layers}) is rejected (step 742). If both conditions are satisfied, the set of values ​​is retained (step 743), i.e. constitutes a possible set of values ​​for determining the weaving grid.

[0103] At the end of the process described in Figure 7, there may be one or more possible combinations, and the user may choose one or more combinations from among these possible combinations.

[0104] Referring again to Figure 2, in step 230, once the composition of the initial cell is determined, all the intermediate weaving grids can be constructed, starting with the intermediate weaving grid comprising the initial cell, then constructing step by step the intermediate weaving grids of the different zones / layers, as described below. The determination of the intermediate weaving grid comprises the determination, for each layer zone typically, of a weft spacing value and a warp spacing value (which therefore define the dimensions of the cells along the (X,Y) axes). For example, the warp and weft spacing values ​​of the intermediate weaving grid associated with the layer zone comprising the zero piece may be equal to the warp and weft spacing values ​​determined for the initial cell (corresponding to the zero piece).For other areas, the intermediate weaving grids can be constructed based on the possible warp / weft spacing values ​​(received in step 220) for those areas.

[0105] Thus, step 230 may comprise, for each layer zone or each layer, the determination of a respectively associated intermediate weaving grid, this determination comprising a determination of a weave from the list of authorized weaves, of a warp yarn count from the list of possible warp yarn counts, of a weft yarn count from the list of possible weft yarn counts and of a weft spacing compatible with the determined warp yarn count, the determined weft yarn count and the predefined target warp spacing value(s).

[0106]

[0107] In one or more embodiments, when the model received in step 210 comprises a plurality of zones (belonging to one or more layers), step 230 comprises determining, for each zone of each layer, a respective intermediate weaving grid, in a manner similar to what has been described previously. In these embodiments, the intermediate weaving grids are created successively for each zone, starting with the zone comprising the zero piece. Then, each intermediate weaving grid corresponding to a new zone is determined based on the intermediate weaving grids already determined for the neighboring zones. Indeed, in these embodiments the Transitions between zones must also be taken into consideration, to avoid incompatibilities between two neighboring weaving grids, for example in terms of weft or warp spacing, or selected weft and / or warp yarn counts. To ensure a "smooth" transition between two neighboring intermediate weaving grids (i.e. associated with zones having adjacent portions, said zones possibly belonging to the same layer or to two different layers), transition grids can be determined. For example, for two neighboring intermediate weaving grids, it is possible to locally modify (around the adjacent portions) the two intermediate weaving grids to ensure continuity of order C1 between them.

[0108] By "neighboring weaving grid" is meant a weaving grid of which at least some cells are adjacent to the cells of the other weaving grid.

[0109] In these embodiments, it is possible to define a processing order for the layers and zones, to ensure that a weaving grid is well determined according to the neighboring weaving grids. For example, for each layer, it is possible to order the zones of this layer according to the distance from their center to the zero piece. It is also possible to classify the layers according to their "neighborhood order" with the layer containing the zero piece: for example, the layer containing the zero piece can be associated with an order 0, the layers having at least one neighboring region with the layer comprising the zero piece can be associated with an order 1, the layers having no neighboring regions with the zero piece but having at least one neighboring region with a layer of order 1 can be associated with an order 2, etc.

[0110] In the example of Figure 3b, if we assume that layer 302d includes the zero part, layer 302d is assigned order 0, layers 302a, 302b, 302e, 302f are assigned order 1, and layer 302c is assigned order 2.

[0111] The weaving grids can then be determined as follows: first, a layer is chosen according to the ascending order of the layers, starting with 0 (two layers of the same order can be treated independently, successively or in parallel), then, for each layer, the weaving grids are successively constructed for the different zones, starting with the zone closest to the zero piece and then considering the zones according to their increasing distance from the zero piece.

[0112] Of course, other orders of determination are possible, as long as they take into account the neighborhood of zones and layers in relation to each other.

[0113] Furthermore, when the object comprises several zones, the authorized armors may be different depending on the zones, and the determined armors may therefore also be different depending on the zones. In this case, step 230 may also comprise the reception of so-called “transition” armors, which correspond to armors determined for the transition zones (i.e. zones comprising cells of a first zone and cells of a second zone neighboring the first zone). These transition armors may advantageously be provided by the user, when the armors of the two neighboring zones are not compatible (for example when the minimum number of layers associated with one of the armors is greater than the maximum number of layers associated with the other armor).In these embodiments, the method may comprise a step of detecting an incompatibility between two armors of two neighboring areas, and of issuing an alert indicating this incompatibility to the user, who can then provide, via a human-machine interface, a list of transition armors for the region concerned.

[0114] In embodiments where the model received in step 210 comprises multiple areas, the method of Figure 2 may include a step 240 in which an initial area is selected to start the population method. For example, this initial area may correspond to the area comprising the zero piece received in step 210 (which belongs to only one area). When the model received in step 210 comprises only one area, step 240 may be omitted.

[0115] During a first iteration of step 250, an initial cell is determined. This initial cell constitutes the starting point of the population method. In other words, the initial cell is the first cell for which the weaving composition is determined. For example, the initial cell determined in step 250 for the initial zone determined in step 240 (or the only zone of the model in the case where it comprises only one zone) may be the cell of the weaving grid associated with the zero piece, i.e. the cell in which the zero piece is located.

[0116] By "weaving composition" is meant a description of the weaving threads (warp and weft) and how they are positioned together. relative to each other in the cell, or, equivalently, a set of data to describe the weaving threads and how they are positioned relative to each other in each cell of the weaving grid. In particular, the data concerns the number of layers associated with each cell, the number of weft and warp threads per layer, the spacing between layers, the spacing between weft and warp threads, the number of weft (resp. warp) threads between two consecutive warp (resp. weft) threads, etc. This data can be represented in the form of a 3D map, as in Figure 4 where some sections of such a map are shown.

[0117] Figure 4 thus represents a weaving grid and weaving compositions for cells of the weaving grid, according to several sections. The weaving grid represented in Figure 4 comprises a plurality of cells 401 a, 401 b, 401 c, 401 d, 401 e. In this figure, the X direction corresponds to that of the warp threads 402a, 402b, 402c (represented with dotted lines) and the Y direction corresponds to that of the weft threads 403a, 403b, 403c (represented with hatching).

[0118] When the current cell is the cell corresponding to the zero piece, step 260 (which corresponds to a step of determining the weaving composition) can be omitted, because the weaving composition of the initial cell has already been determined in step 230. In step 270, it is checked whether all the cells of the area considered have been populated (i.e. whether step 260 of determining the weaving composition of a cell has been implemented for all the cells of the current area). If all the cells have not yet been populated (step 275, arrow “N”), a new cell is considered (step 275) and the step of determining the weaving composition (step 260) is implemented for this new cell. When all the cells have been populated (step 270, arrow “O”), and in the case where the model received in step 210 comprises a plurality of zones, it is checked in step 280 whether all the zones of the model have been populated.If some areas of the model have not yet been populated (step 280, arrow "N"), a new area is considered (step 285), a new initial cell is determined for the new area considered (step 250), and the determination of the weaving composition for the cells of the new area is implemented (steps 260, 270 and 275). When all areas of the model have been populated (step 280, arrow "O"), the population method is finished. It is then possible, for example, to represent. graphically the 3D mapping of the part (step 290). Alternatively or in addition, step 290 may comprise representing successive sections of the 3D mapping in the form of “weaving boxes”, the boxes being able to be used as input data for the loom to manufacture the woven reinforcement of the part.

[0119] When the model includes only one zone, steps 280 and 285 may be omitted.

[0120] In step 275, the determination of the new cell is performed from a predefined path of the weaving grid / intermediate weaving grid. An example of such a path is shown in Figure 5.

[0121] In the example of Figure 5, two intermediate weaving grids 502a and 502b are shown, and correspond respectively to two neighboring areas of the model. In this example, the intermediate weaving grid 502a is assumed to include the zero piece 503. The zero piece 503 separates the intermediate grid 502a into four quadrants 501a, 501b, 501c and 501d, the first quadrant 501a including the zero piece 503. As mentioned above, the zero piece 503 is the first cell for which the weaving composition is determined. Then, the cells are filled (or "populated") step by step according to a predefined path. In the example of Figure 5, this predefined path starts at room zero 503 and continues in a given direction (here, along the lines from left to right, i.e. along the X-oriented direction) 504a inside the first quadrant 501a.When the last cell 505 of the first quadrant row 501a has been populated, the row directly above 504b is populated, starting with cell 506 directly above room zero 503.

[0122] The other three quadrants 501 b, 501 c, 501 d may be populated in a similar manner. For example, the second quadrant 501 b may be populated by starting with cell 507 directly adjacent to the zero piece 503, then populating the cells step by step in a direction 508 a opposite to the direction 504 a of the first quadrant 501 a, and moving up the rows in the Y direction similarly to the first quadrant 501 a.

[0123] The four quadrants 501 a, 501 b, 501 c, 501 d can be populated successively or in parallel, once the zero piece 503 has been populated.

[0124] When the four quadrants 501 a, 501 b, 501 c, 501 d have been populated, the loop of steps 260-270-275 of Figure 2 is completed for the current area, and the next area is selected if applicable (step 285 of Figure 2). The next area can be selected as previously described for the determination 230 of the weaving grid.

[0125] Referring again to Figure 5, once the first intermediate weaving grid 502a is populated, it is assumed that the second intermediate weaving grid 502b is selected to be populated in turn. A new initial cell 509 must be selected to begin the population of the second intermediate weaving grid 502b (new step 250). For example, the new initial cell 509 can be any cell neighboring a cell of the already populated first intermediate weaving grid 502a.

[0126] When implementing an iteration of step 260, the weaving composition of the current cell is therefore determined. This determination is made from the weave of the current area determined in step 230, as well as the weft and warp yarns of the current cell determined in step 230, so as to jointly the difference between the volume fraction of fiber in the cell thus filled and the target volume fraction of fiber and the difference between the RCT in the cell thus filled and the target RCT, while taking into account the neighboring cells already filled. In particular, the number of layers of the current cell depends on the number of layers of the neighboring cells already filled.For example, it may be imposed that the number of layers of the current cell is between: the minimum of the numbers of layers of the neighboring cells already filled minus a first predetermined authorized variation; and the maximum of the numbers of layers of the neighboring cells already filled plus a second predetermined authorized variation.

[0127] Furthermore, if the predefined values ​​of the parameters relating to manufacturing constraints received in step 220 include a maximum number or a minimum number of layers, this number can be taken into account to determine the number of layers of the current cell in step 260.

[0128] Additionally, rules for the number of layers can be predefined, to determine when the number of layers in a cell should be reduced or increased compared to the number of layers of the cell filled in the previous step. These rules are generally defined by the textile department and are part of the parameters relating to the manufacturing constraints received in step 220. They may in particular concern constraints relating to an alternation of the threads or constraints of continuity in the number of layers.

[0129] The number of layers of the current cell can also be determined from the weave selected in step 230 for the area comprising the current cell (current area). Indeed, depending on the type of part to be manufactured, certain weaving rules may be imposed, for example to only perform a division of threads when the weave applied to the area belongs to a predefined weave group. If the weave applied to the area does not belong to this weave group, it is not possible to divide the threads, and therefore the number of layers in the current cell must be the same as in the neighboring cells.

[0130] According to an example of implementation, each cell can be modeled by a data matrix, each component of this matrix representing information relating to the thread present in the portion of the cell corresponding to the component of the matrix (each component can for example take one of the following values: a first value indicating that there is no thread in the portion of the cell considered, a second value indicating that there is a weft thread in the portion of the cell considered, and a third value indicating that there is a warp thread in the portion of the cell considered). Of course, other implementations are possible.For example, two matrices of the same dimension may be associated with each cell, one corresponding to the warp threads and the other to the weft threads, and for each of the two matrices, the components may be equal to 0 if no thread of the type concerned is present in the corresponding regions, and to a value representative of the thread count used if a thread of the type concerned is present in the corresponding regions. According to another example implementation, a 3D representation of the woven piece may be represented by a 3D matrix containing cells, each cell representing a warp / weft crossing, in which it is indicated whether or not the warp thread is taken by the weft thread. This 3D matrix is ​​constructed from the model of the piece received in step 210 (for example the thickness maps), the weaving grids and the weaving compositions determined in steps 230 to 280.

[0131] The weave compositions determined for cells in already populated areas and neighboring cells in a new, not yet populated area can be used as input data to populate this new area. The same applies to the different layers of the model, if applicable.

[0132] The method of Figure 2 can advantageously be applied in parallel for several possible weaving grids (as defined in step 230). Indeed, it may happen that, for a given weaving grid, the method cannot result in filling all the cells while respecting the manufacturing constraints. In this case, this weaving grid is discarded, and only the weaving grids for which all the cells of the model could be filled are retained. Furthermore, the parallel application of the method for several weaving grids makes it possible, at the end of the method, to determine “global” parameters on the filled weaving grids, for example an average number of layers, or an average volume fraction over all the cells of a filled weaving grid.It is then possible to select, from all the filled weaving grids, the one whose global parameters are closest to the manufacturing constraints.

[0133] Figure 6 represents a device for determining the values ​​of the firing parameters for a projectile ingestion test on a blade in a static position, according to one or more embodiments of the invention.

[0134] In these embodiments, the device comprises a computer 600, comprising a memory 601 for storing instructions allowing the implementation of the method, the predefined values ​​of parameters relating to manufacturing constraints, and temporary data for carrying out different steps of the methods described previously.

[0135] The computer 600 further comprises a circuit 602. This circuit may be, for example, a processor capable of interpreting instructions in the form of a computer program, an electronic card whose steps of the method of the invention are described in the silicon, or even a programmable electronic chip such as an FPGA chip (for “Field-Programmable Gate Array” in English).

[0136] The computer 600 comprises an input interface 403 for receiving the model of the part to be manufactured and predefined values ​​of parameters relating to manufacturing constraints, and an output interface 604 for providing the weaving mapping. Finally, the computer may include, to allow easy interaction with a user, a screen 605 and a keyboard 606. Of course, the keyboard is optional, particularly in the context of a computer in the form of a touch pad, for example.

[0137] Furthermore, the functional diagram presented in Figure 2 is a typical example of a program, certain instructions of which can be carried out using the device described. In this respect, Figure 2 may correspond to the flowchart of the general algorithm of a computer program within the meaning of the invention.

[0138] Of course, the present invention is not limited to the embodiments described above as examples; it extends to other variants.

Claims

CLAIMS

1. A computer-implemented method for determining a weaving map of an area (301 a, 301 b, 301 c, 301 d) of a part to be manufactured from a woven composite material, comprising: - receive (210) a representation of said area of ​​the part; - receive (220) predefined values ​​of parameters relating to manufacturing constraints of the area of ​​the part; - determining (230), from the representation of the area of ​​the part and a first subset of values ​​among the predefined values ​​received, a weaving grid of the area of ​​the part, the weaving grid comprising a plurality of cells (401a, 401b, 401c, 401d, 401e); and - determining (260) successively, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​among the predefined values ​​received; wherein the determination (260) of a weaving composition for a current cell of the weaving grid depends on a weaving composition already determined for a cell of the weaving grid adjacent to the current cell; and wherein the weaving mapping of the area of ​​the part comprises the cells of the weaving grid and the respective weaving compositions.

2. The method of claim 1, wherein the first subset of values ​​among the received predefined values ​​comprises a list of authorized weaves, a list of authorized weft yarn counts, a list of authorized warp yarn counts and one or more target warp spacing values; wherein determining the weaving grid of the area of ​​the part comprises: - select an armor for the area from the list of authorized armors; - select a weft thread title for the area from the list of authorized weft thread titles; select a warp thread title for the area from the list of allowed warp thread titles; - determining a warp spacing value from among the one or more target warp spacing values ​​and the selected warp yarn count; and - determine a weft spacing for the area based on the selected warp yarn count, the selected weft yarn count, and the determined target warp spacing value.

3. A method according to one of the preceding claims, wherein, for each cell (401a, 401b, 401c, 401d, 401e) of the weaving grid, the respective weaving composition comprises a set of parameters representative of a number of weft threads (403a, 403b, 403c) and warp threads (402a, 402b, 402c) and of a relative arrangement of the weft threads (403a, 403b, 403c) and warp threads (402a, 402b, 402c) in said each cell (401a, 401b, 401c, 401d, 401e) of the weaving grid.

4. A method according to one of the preceding claims, wherein the representation of said area (301a, 301b, 301c, 301d) of the received part comprises thickness data representing thicknesses of the area of ​​the part at a plurality of points in the area of ​​the part, wherein determining (260) the weave composition for a current cell of the weaving grid comprises: determining a number of weave layers in the current cell as a function of thickness data representing a thickness at a point in the area of ​​the part corresponding to the current cell and as a function of at least one number of weave layers already determined for at least one respective cell of the weaving grid adjacent to the current cell.

5. A method according to any preceding claim, wherein the second subset of parameters relating to manufacturing constraints of the area of ​​the part comprises a target fiber volume fraction value and a target warp-to-weft ratio value; wherein the weave composition of a cell of the weaving grid is determined so as to jointly minimize a deviation between a fiber volume fraction value in the cell and the target warp-to-weft ratio value; target fiber volume and a deviation between a warp-to-weft ratio value in the cell and the target warp-to-weft ratio value.

6. A computer-implemented method of determining a weave map of a part to be manufactured from a woven composite material, comprising: - receiving a plurality of zones (301a, 301b, 301c, 301d) of the part to be manufactured, in which each zone comprises at least one portion adjacent to a portion of another zone; - for each zone among the plurality of zones (301 a, 301 b, 301 c, 301 d), successively determining weaving maps of said each zone by the method according to one of claims 1 to 5; wherein the determination of the weaving map of a current zone is a function of the weaving map of a zone other than the current zone for which the respective weaving map has been determined, the current zone comprising a portion adjacent to a portion of the other zone.

7. The method of claim 6, wherein determining the weave mapping for the current area comprises: - identify a cell of the current area adjacent to at least one cell of the other area for which the respective weave mapping has been determined; and - determining the weave composition for the identified cell from the at least one weave composition determined for the at least one adjacent cell of the respective other area.

8. Method according to one of the preceding claims, in which the part to be manufactured is an aeronautical part.

9. A method of manufacturing a part in a woven composite material comprising: determining a weaving map of the part according to one of claims 6 and 7; and manufacture the part from the determined part weaving map.

10. Device for determining a weaving map of an area (301a, 301b, 301c, 301d) of a part to be manufactured in a woven composite material, comprising: - an input interface for receiving (210) a representation of said area of ​​the part and predefined values ​​of parameters relating to manufacturing constraints of the area of ​​the part (220); - at least one circuit for: o determining (230), from the representation of the area of ​​the part and a first subset of values ​​among the predefined values ​​received, a weaving grid of the area of ​​the part, the weaving grid comprising a plurality of cells (401 a, 401 b, 401 c, 401 d, 401 e); and o determining (260) successively, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​among the predefined values ​​received; wherein the determination (260) of the weaving composition for a current cell of the weaving grid depends on a weaving composition already determined for a cell of the weaving grid adjacent to the current cell; and wherein the weaving mapping of the area of ​​the part comprises the cells of the weaving grid and the respective weaving compositions.

11. A system for determining a weave mapping of a part to be manufactured from a woven composite material, the part to be manufactured comprising a plurality of zones, wherein each zone comprises at least one portion adjacent to a portion of another zone, the system comprising a plurality of devices according to claim 10, each device being configured to determine a weave mapping of a respective zone among the plurality of zones; wherein the determination of the weave mapping of a current zone is a function of the weave mapping of an area other than the current zone for which the respective weave mapping was determined, the current area comprising a portion adjacent to a portion of the other area.

12. A system for manufacturing a part in a woven composite material comprising: - a system for determining a weave map of the part according to claim 11; and - a loom to manufacture the piece from the weaving map of the determined piece.

13. Computer program product comprising instructions for implementing the method according to one of claims 1 to 8 when this program is executed by a processor.

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