METHOD FOR DETERMINING A WEAVE MAP

Abstract

METHOD FOR DETERMINING A WEAVE MAP One aspect of the invention relates to a method for determining a weave map of an area of ​​a part to be manufactured in a woven composite material, comprising: 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 and a first subset of values ​​among the predefined values ​​received, a weave grid of the area of ​​the part, the weave grid comprising a plurality of cells; and successively determining, for each cell of the weave grid, a respective weave composition compatible with a second subset of values ​​among the predefined values ​​received. Figure to be published with the abstract: Figure 2

Description

Title of the invention: METHOD FOR DETERMINING A WEAVE MAP TECHNICAL FIELD OF THE INVENTION

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

[0002] In particular, the invention relates to the design of a one-piece woven reinforcement by creating a weaving map representing the weaving structure of the reinforcement before manufacturing it. TECHNOLOGICAL BACKGROUND OF THE INVENTION

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

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

[0005] Manufacturing a part from a woven composite material therefore requires a first manufacturing step (or "making") of the reinforcement by weaving, followed by a second assembly step with the matrix, for example by injection molding after shaping in a mold. At the end of the first manufacturing step of the reinforcement by weaving, a woven reinforcement, also called a "preform," is obtained.

[0006] For example, in the resin transfer molding process, the preform is placed in a rigid mold, 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 the woven reinforcement, i.e. the preform, is a complex process, which This requires in-depth knowledge of material properties derived from the structure and type of reinforcement, as well as manufacturing processes. Indeed, the composite material must possess certain mechanical characteristics, which are defined by the design office according to the type of part, while its manufacturing process is subject to various constraints.

[0008] Thus, the design of the woven reinforcement requires significant preliminary work during which an optimal compromise must be found between the requirements relating to material characteristics and the constraints imposed by the weave. Software exists that incorporates algorithms for optimizing textile layers, but this software does not take into account the constraints imposed by the weave or the optimization of the weave structure. Therefore, programming a textile component requires considerable time (on the order of several months for a complex component), 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 allowing the architecture of the woven reinforcement to be designed automatically and quickly according to a set of manufacturing constraints.

[0011] One aspect of the invention relates to a computer-implemented method for determining a weave map of an area of ​​a part to be manufactured from a woven composite material. The method may include: • receive a representation of said area of ​​the room; • receive predefined parameter values ​​related to manufacturing constraints of the part area; • determine, from the representation of the room area and a first subset of values ​​from among the predefined values ​​received, a weaving grid of the room area, the weaving grid comprising a plurality of cells; and • successively determine, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​from among the predefined values ​​received; in which the determination of a 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

[0012] wherein the weaving mapping of the area of ​​the piece includes the cells of the weaving grid and the respective weaving compositions.

[0013] By "weave map," we mean a set of data that represents the weave associated with an area of ​​a mechanical part (for example, a woven reinforcement). By "weave composition," we mean a set of data that characterizes the weave in the area concerned, including the type of yarns used and how the yarns are arranged relative to each other. In other words, the weave composition fully defines the weave within a cell, and the weave map corresponds to the set of weave compositions for the cells. Thus, the weave map represents the weave architecture of the area of ​​the mechanical part.

[0014] The term "zone" refers to 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, a small one, for which the manufacturing constraints are the same at every point of the part).

[0015] The parameters relating to manufacturing constraints of the area are parameters representing criteria to be met for the design of the weave, which are typically determined or validated beforehand 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 (for example, the foot and the head of an engine blade), the parameter values ​​may differ.

[0016] The term "weave grid" refers to a mesh of the area of ​​the part under consideration. Determining the weave grid therefore includes determining this mesh, and in particular the dimensions of the cells. This determination is advantageously carried out using a first subset of values ​​from among the predefined values ​​of the parameters relating to the received manufacturing constraints.

[0017] The term "weave composition" refers to a set of parameters used to characterize the weave (number of warp and weft threads, relative arrangement of the threads, number of layers, etc.). For each cell of the weave grid, the weave composition is determined using a second subset of values ​​from among the predefined values ​​of the parameters relating to the manufacturing constraints received. Thus, the determined composition advantageously takes into account the manufacturing constraints imposed for the part.

[0018] By "current cell" is meant a cell for which the weave composition is determined (i.e., the cell under consideration at a current stage of the process), as opposed to cells for which the compositions have already been determined and to cells for which the determination of the weave composition is carried out at stages subsequent to the current stage. By "adjacent cell" (or neighboring cell), it is understood to be a cell belonging to a predefined neighborhood of the cell in the weaving grid, for example a 4-connected neighborhood.

[0019] 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 is determined for one cell, the weave composition is determined for another cell, and so on until all the cells of the grid have been examined. By "weave composition already determined for a cell," it is therefore understood that a weave composition was determined for a cell different from the current cell in a step prior to the current step.

[0020] According to this process, the weaving composition of a cell advantageously takes into account the weaving compositions already determined for neighboring cells, thus avoiding structural problems in the weaving composition (for example, incompatible weaving compositions between adjacent cells).

[0021] 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, at least one two-dimensional model of the part may include at least one thickness map of the part area.

[0022] By "thickness map of the part area" is meant a set of data enabling the characterization of 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 map can be in the form of an image showing the contour, in which each pixel inside the contour is associated with a value that depends on the thickness of the part at that pixel.

[0023] 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 carried out according to a traversal order of the cells of the weaving grid, a starting point of which corresponds 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.

[0024] 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.

[0025] In one or more embodiments, the determination of the weaving composition for the current cell of the weaving grid depends on all the weaving compositions already determined for the cells of the weaving grid adjacent to the current cell.

[0026] In one or more embodiments, the first subset of values ​​from among the predefined values ​​received may include a list of allowed weaves, a list of allowed weft yarn titles, a list of allowed warp yarn titles, and one or more target warp spacing values. The determination of the three-dimensional weave grid of the part area may include: • select an armor for the area from the list of allowed armors; • Select a wire title for the area from the list of wire titles in allowed frames; • select a thread title for the area from the list of allowed thread titles; • determine a string spacing value from among one or more target string spacing values ​​and the selected string thread title; and • determine a frame spacing for the area based on the selected warp thread title, the selected weft thread title and the determined target warp spacing value.

[0027] In one or more embodiments, the respective weaving composition may comprise a set of parameters representative of a number of weft and warp yarns and a relative arrangement of the weft and warp yarns in said each cell of the weaving grid.

[0028] For example, for each cell of the weaving grid, determining the respective weave composition may include: associating each cell with a respective vector, and assigning to each component of the vector a value indicating the presence or absence of a yarn at a position corresponding to that component in the cell, and an associated yarn type. The yarn type may be one of: a warp yarn and a weft yarn.

[0029] In one or more embodiments, the representation of said area of ​​the received part may include thickness data representing thicknesses of the area of ​​the part at a plurality of points of the area of ​​the part, and the determination of the weave composition for a current cell of the weave grid may include: determining a number of weave layers in the current cell as a function of a thickness data representing a thickness at a point of the area of ​​the part corresponding to the current cell and as a function of at least a number of weave layers already determined for at least one respective cell of the weave grid adjacent to the current cell.

[0030] 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 weave composition has already been determined.

[0031] In one or more embodiments, the second subset of parameters relating to manufacturing constraints of the part area may include a target fiber volume fraction value and a target warp-to-weft ratio value. The weave composition of a cell in the weaving grid may be determined so as to jointly minimize a difference between a fiber volume fraction value in the cell and the target fiber volume fraction value, and a difference between a warp-to-weft ratio value in the cell and the target warp-to-weft ratio value.

[0032] 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 in the weaving grid may be determined such that a fiber volume fraction value in the cell belongs to the range of target fiber volume fraction values ​​and a warp-to-weft ratio value in the cell belongs to the range of target warp-to-weft ratio values.

[0033] A combination of these embodiments is of course possible (minimizing the gap between the value obtained and the target value for one of the parameters, and determining the value so that it belongs to the range of target values ​​for the other parameter).

[0034] Another aspect of the invention relates to a computer-implemented method for determining a weave map of a part to be manufactured from a woven composite material. The method may include: • receive a plurality of zones of the part to be manufactured, in which each zone includes at least one portion adjacent to a portion of another zone; • for each zone among the plurality of zones, successively determine weaving maps of said each zone by the above process; in which the determination of the weave mapping of a current area is a function of the weave mapping of an area other than the 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.

[0035] In these embodiments, the determination of the weave mapping for the current area may include: • identify a cell in the current zone adjacent to at least one cell in the other zone for which the respective weave mapping has been determined; and • determine the weave composition for the identified cell from at least one weave composition determined for at least one adjacent cell in the other respective area.

[0036] Thus, the adjacent areas for which the weaving maps have already been determined are advantageously taken into account for the determination of the weaving map of a current area.

[0037] The plurality of zones may include groups of zones, each group of zones being respectively associated with a layer of the part to be manufactured.

[0038] In one or more embodiments, the part to be manufactured may be an aeronautical part.

[0039] Another aspect of the invention relates to a method for manufacturing a part from a woven composite material which may include: • determine a weaving map of the piece according to one of the above processes; • to manufacture the part from the determined weave map of the part.

[0040] Another aspect of the invention relates to a device for determining a weave map of an area of ​​a part to be manufactured in a woven composite material. The device may include: • an input interface to receive a representation of said area of ​​the part and predefined parameter values ​​relating to manufacturing constraints of the area of ​​the part; • at least one circuit for: • determine, from the representation of the room area and a first subset of values ​​from among the predefined values ​​received, a weaving grid of the room area, the weaving grid comprising a plurality of cells; and • successively determine, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​from among the predefined values ​​received; in which 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

[0041] wherein the weaving mapping of the area of ​​the piece includes the cells of the weaving grid and the respective weaving compositions.

[0042] 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, in which each zone comprises at least a 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; in which the determination of the weave mapping of a current area is a function of the weave mapping of an area other than the 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.

[0043] The invention also relates to a system for manufacturing a part from a woven composite material, which may include: • a system for determining a weave map of the piece as before; and • a loom to manufacture the piece from the determined weaving map of the piece.

[0044] A computer program, implementing all or part of the process described above, installed on pre-existing equipment, is in itself advantageous.

[0045] Thus, the present invention also relates to a computer program product comprising instructions for the implementation of certain steps of the processes described above, when this program is executed by a processor.

[0046] This program may use any programming language (for example, an object-oriented language or other), and may be in the form of interpretable source code, partially compiled code or fully compiled code.

[0047] The [Fig.2] described in detail below can form the flowchart of the general algorithm of such a computer program.

[0048] 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

[0049] Other features and advantages of the invention will become apparent from the description, which can be read in conjunction with the figures. These figures are provided for illustrative purposes only and are not intended to limit the scope of the invention.

[0050] [Fig.1] Fig.1 represents an example of a woven composite material.

[0051] [Fig.2] Fig.2 represents a flowchart of a method for determining a weaving mapping for a part to be manufactured in a woven composite material, according to an embodiment.

[0052] [Fig.3a] Fig.3a represents an example of regions of a part to be manufactured in a woven composite material.

[0053] [Fig.3b] Fig.3b represents an example of layers of a part to be manufactured in a woven composite material.

[0054] [Fig.4] Fig.4 represents several cross-sections of a weaving grid from a portion of a part to be manufactured in a woven composite material, according to a method of embodiment.

[0055] [Fig. 5] Fig. 5 represents a traversal order of the weaving grid, according to a method of implementation.

[0056] [Fig.6] The [Fig.6] represents a device configured to implement steps of the process of determining a weave map for a part to be manufactured in a woven composite material, according to an embodiment.

[0057] [Fig. 7] [Fig. 7] represents an example of a method for determining the weave composition of an initial cell according to one embodiment. DETAILED DESCRIPTION

[0058] [Fig.2] Fig.2 represents a flowchart of a process for determining a weaving map for a part to be manufactured in a woven composite material, according to one or more embodiments.

[0059] By "weave map," we mean a spatial representation of the structure (i.e., the different types of yarns used and how they are entangled) of the reinforcement of the part to be manufactured, this map being subsequently used to weave said reinforcement according to the determined structure. By extension, the term "weave map" also refers to a set of data characterizing or enabling the creation of the spatial representation of the structure of the woven reinforcement.

[0060] 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, for example, be a 2D thickness map, that is, a 2D model representing a contour of the part (typically the contour of a 2D projection of the part onto an (X,Y) plane) and, for each point inside the contour, a thickness value of the part at that point along a third direction (for example, Z). The model received in step 210 may further include data relating to different areas of the part, the different areas of the part corresponding to regions of the part whose properties or weaving constraints differ from one another.

[0061] An example of such regions is shown in [Fig. 3a]. In the example in [Fig. 3a], the part to be manufactured is an aircraft engine blade, and four zones 301a, 301b, 301c, 301d of the part are predefined. In this example, zones 301a, 301b, 301c, 301d correspond to four regions subdividing the blade along its longitudinal axis. Of course, depending on the embodiment, the number of zones may differ from 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 [Fig. 3a], zones 301a, 301b, 301c, and 301d represent regions of the part where the desired mechanical properties and weaving constraints are not necessarily the same from one region to another. In contrast, the mechanical properties desired and weaving constraints do not vary within a predefined area.

[0062] Furthermore, in one or more embodiments, the model of the part to be manufactured received during step 210 of [Fig. 2] may comprise a plurality of "layers", i.e., a set of strata, some of which are superimposed (partially or totally), generally defined by an expert and intended for use in computer-aided design software. An example of layers is shown in [Fig. 3b].

[0063] As illustrated in [Fig. 3b], the object model comprises a plurality of layers 302a, 302b, 302c, 302d, 302e, 302f, represented in the left-hand diagram in an (X,Y) coordinate system and in the right-hand diagram in a (Y,Z) coordinate system. Each layer can itself be composed of one or more zones as defined previously with reference to [Fig. 3a]. Thus, in certain embodiments, the part model received in step 210 of [Fig. 2] can comprise a plurality of 2D representations respectively associated with the different layers and the different zones. For example, a 2D thickness map can be received for each layer, the thickness map 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 in [Fig.3b].Depending on the implementation methods, there may be a single layer, or any (integer) number of layers, or even no layers at all (the part is then represented by a 2D model comprising one or more zones).

[0064] Referring again to [Fig. 2], in one or more embodiments, the coordinates of a reference point, also called the "piece zero," can be obtained in step 210. Advantageously, this reference point belongs to a single area 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 weave composition in the different cells of the model (also called the "population" of the cells). The coordinates of the piece zero are conventionally set to (0,0,0) in the three-dimensional orthogonal coordinate system (X,Y,Z).

[0065] During step 220, a set of predefined parameter values ​​relating to manufacturing constraints is received. These are predetermined values, which correspond to target values ​​(i.e., values ​​that one wishes to achieve through the process) or imposed values ​​(for example, by the loom or by constraints related to the part to be manufactured known to experts in the field). These predetermined values ​​are typically 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 desired mechanical characteristics for the part (necessary for the part to (which can be certified and used subsequently), and can therefore relate to the yarns used and / or the way the yarns are arranged, such as the warp-to-weft ratio or the fiber volume fraction. It should be noted that the warp-to-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 given volume of the composite material (reinforcement and matrix).

[0066] The predefined values ​​can be associated with a specific area of ​​the model received in step 210. Thus, in step 220, several sets of values ​​can be received, each set being associated with a respective area.

[0067] For example, taking up again the example of [Fig. 3a], of the sets of values ​​of RCT and of The respective FV values ​​can be received at step 220 for zones 301a (blade foot), 301b (lower midsection), 301c (upper midsection), and 301d (blade tip). For each zone 301a, 301b, 301c, and 301d, the RCT and / or FV value can be one or more point values, or a range of values.

[0068] 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 because of the part itself (for example, due to its geometry and future use - for example, a blade and an engine retaining housing are not made using the same weaving method), or because of the loom used (which may, for example, not allow the use of all weaves or all types of yarn).Thus, the predefined values ​​of the parameters received in step 220 may also include, but are not limited to, one or more of the following values: one or more permitted weaves, a target value (or range of values) for weft spacing, a target value (or range of values) for warp spacing, one or more possible yarn counts in weft, one or more possible yarn counts in warp, 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.

[0069] It is recalled that the weave corresponds to the pattern of yarn assembly (the interlacing pattern of the warp and weft). The weft (or warp) spacing corresponds to the distance between two successive weft (or warp) yarns. The yarn "count" corresponds to the type of yarn, characterized by its linear density, 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 of "Xk" corresponds to a yarn comprising Xxl000 fibers per yarn. The list of available yarn counts may differ between the warp and the weft. The maximum (or minimum) number of textile layers corresponds to the maximum (or minimum) number of textile layers that a yarn of The warp can (or must) pass 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 (or minimum) number of warps (or wefts) represents the maximum (or minimum) number of warp (or weft) yarns in a warp / weft plane (X,Y).

[0070] A weaving grid is then determined in a step 230. In one or more embodiments, the weaving grid may comprise a plurality of grids, referred to herein as "intermediate weaving grids" 2D, each intermediate weaving grid being, for example, respectively associated with a layer among the plurality of layers received, if applicable, in step 210 and / or with an area among the plurality of areas received, if applicable, in step 210. When the model comprises only one layer (or no layers) and only one area, there may be only one intermediate grid, which constitutes the weaving grid.

[0071] Each intermediate weaving grid can comprise a plurality of cells, for example nx x nY cells distributed along the warp and weft axes (X,Y). Each cell of an intermediate weaving grid can be associated with a thickness value, which represents the cell thickness in a third direction Z. The cell thickness values ​​are variables, which are among the parameter values ​​that the described process proposes to determine.

[0072] During step 230, the intermediate weaving grids are determined for all layers and / or all areas 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 an area of ​​a layer for example, the associated weaving grid can represent a mesh of said area 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.

[0073] According to one embodiment, step 230 may include a first step of determining the weave 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 weave grids respectively associated with these zones / layers begins with the determination of the intermediate weave grid associated with the zone / layer containing the zero piece, and with a first step of determining the weave composition of the cell associated with the zero piece. Once the intermediate weave grid associated with the layer / zone containing the zero piece is determined, the other intermediate weave grids can in turn be determined in an order specified below.

[0074] During this first step of determining the weave composition of the For the initial cell, one or more combinations of values ​​are determined for the following parameters: weave, warp and weft yarn counts, warp spacing, and weft spacing. A number of layers for the initial cell is also determined. These combinations of values ​​are determined to be compatible with the weaving constraints, i.e., with the parameter values ​​related to manufacturing constraints received in step 220.

[0075] 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 have to choose one or more combinations from among the compatible combinations to continue the process of [Fig.2].

[0076] In one or more embodiments, this first step of determining the weave composition of the initial cell may also include determining the number of layers in the initial cell (i.e., corresponding to the zero piece) and determining the 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 piece thickness, provided as input with the piece model during step 210 (typically the value indicated by the thickness mapping at the point corresponding to the zero piece). 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 cell thickness, and a target fiber volume fraction.

[0077] An example of implementation of this first step of determining the weaving composition of the initial cell according to one embodiment is shown in [Fig.7].

[0078] The inputs of this first determination step are: the list of possible warp yarn titles, the list of possible weft yarn titles, a warp spacing, a target volume fraction, a target warp-to-weft ratio, a minimum number of layers and a maximum number of layers for the cell, and a minimum and maximum weft spacing for the cell.

[0079] In a first series of steps 710, a frame spacing and a number of layers in the initial cell are determined for each possible combination {warp yarn; weft yarn] from the list of possible warp yarn titles and the list of possible weft yarn titles. For example, if the list of possible warp yarn titles includes 3 yarn titles and the list of possible weft yarn titles includes 2 yarn titles, the frame spacing and the number of layers are determined for the 3 x 2 = 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.

[0080] For each combination {warp thread; weft thread] among the set of possible combinations, an initial frame spacing is calculated during a step 711. This initial frame spacing can be calculated as a function of the warp spacing and the target warp-to-weft ratio:

[0081] FLinit = fFL(string spacing, target RCT).

[0082] Then, a cell thickness can be determined in step 712 as a function of the initial frame spacing calculated in step 711:

[0083] t = ft(FLinit).

[0084] 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):

[0085] NBinit = fNB(warp yarn, weft yarn, FLinit, target FV, t).

[0086] The frame 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:

[0087] FL = fFL(warp yarn, weft yarn, NBinit, target FV, t).

[0088] Finally, the number of layers in the cell can be updated during a step 715, depending on the warp yarn count, the weft yarn count, the weft spacing updated in step 714, the target FV and the thickness determined in step 712:

[0089] NB = fNB(warp yarn, weft yarn, FL, target FV, t).

[0090] Once the frame 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 differs 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 with respect to variations in the frame spacing and 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 implemented directly.

[0091] 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 stability test 734 on the number of layers.

[0092] The frame spacing can 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 VF and the cell thickness determined in step 712:

[0093] FL = fFL(warp yarn, weft yarn, NB, target FV, t).

[0094] Then, the cell thickness can be updated at step 732 based on the frame spacing calculated at step 731:

[0095] t = ft(FLinit).

[0096] 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:

[0097] NB = fNB(warp yarn, weft yarn, FL, target FV, t).

[0098] Finally, a stability test 734 on the number of layers is implemented, in which it is verified 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 to 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 can be, for example, a difference between the current value of the number of layers and the previous value of the number of layers that is less than a predetermined threshold, and / or a difference between the current value of the number of layers and the minimum number of layers that is less than a predetermined value (in other words, with this latter criterion, it is verified whether the minimum number of layers is reached).

[0099] If the convergence criterion is not met (test 734, arrow "ko"), a new iteration of the series of steps 730 is implemented. If the convergence criterion is met (test 734, arrow "ok"), the series of steps 740 is implemented.

[0100] 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).

[0101] During test 741, two cumulative conditions may be verified:

[0102] 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

[0103] 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.

[0104] If at least one of the two conditions is not met, 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 met, the set of values ​​is retained (step 743), that is, it constitutes a possible set of values. for determining the weaving grid.

[0105] At the end of the process described in [Fig.7], there may be one or more possible combinations, and the user may choose one or more combinations from among these possible combinations.

[0106] Referring again to [Fig. 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, and then progressively constructing the intermediate weaving grids of the different areas / layers, as described below. Determining the intermediate weaving grid involves determining, for each layer area typically, a weft spacing value and a warp spacing value (which thus define the cell dimensions along the (X,Y) axes). For example, the warp and weft spacing values ​​of the intermediate weaving grid associated with the layer area comprising the zero piece can be equal to the warp and weft spacing values ​​determined for the initial cell (corresponding to the zero piece).For the other areas, the intermediate weaving grids can be constructed based on the possible warp / weft spacing values ​​(received in step 220) for those areas.

[0107] Thus, step 230 may include, for each layer area or each layer, the determination of an intermediate weave grid respectively associated, this determination including a determination of a weave from the list of permitted weaves, a warp yarn count from the list of possible warp yarn counts, a weft yarn count from the list of possible weft yarn counts and a weft spacing compatible with the determined warp yarn count, the determined weft yarn count and the predefined target warp spacing value(s).

[0108]

[0109] 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 involves determining, for each zone of each layer, a respective intermediate weaving grid, in a manner similar to that described previously. In these embodiments, the intermediate weaving grids are created successively for each zone, starting with the zone containing 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 of the selected weft and / or warp yarn counts.To ensure a transition. "Smooth" between two adjacent intermediate weaving grids (i.e., associated with areas having adjacent portions, these areas potentially belonging to the same layer or two different layers), transition grids can be defined. For example, for two adjacent intermediate weaving grids, it is possible to locally modify (around the adjacent portions) the two intermediate weaving grids to ensure continuity of order Cl between them.

[0110] 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.

[0111] In these embodiments, it is possible to define a processing order for layers and areas to ensure that a weaving grid is correctly determined based on neighboring weaving grids. For example, for each layer, it is possible to sort the areas of that 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 of 0, layers having at least one region adjacent to the layer containing the zero piece can be associated with an order of 1, layers having no regions adjacent to the zero piece but having at least one region adjacent to a layer of order 1 can be associated with an order of 2, and so on.

[0112] On the example of [Fig.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 an order 2.

[0113] The weaving grids can then be determined as follows: first, a layer is chosen according to the increasing 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 areas starting with the area closest to the zero piece and then considering the areas according to their increasing distance from the zero piece.

[0114] Of course, other orders of determination are possible, provided that they take into account the proximity of the zones and layers to each other.

[0115] Furthermore, when the object comprises several zones, the permitted armors may differ from zone to zone, and the determined armors may therefore also differ from zone to zone. In this case, step 230 may also include the receipt of so-called "transition armors," which correspond to armors determined for the transition zones (i.e., zones comprising cells from a first zone and cells from a second zone adjacent to the first zone). These transition armors may advantageously be provided by the user when the armors of the two adjacent zones are not compatible (for example, when the number of layers (minimum associated with one of the armors is greater than the maximum number of layers associated with the other armor). In these embodiments, the process may include a step of detecting an incompatibility between two armors of two neighboring areas, and 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.

[0116] In embodiments where the model received in step 210 comprises several zones, the process of [Fig. 2] may include a step 240 in which an initial zone is selected to start the population method. For example, this initial zone may correspond to the zone containing the zero part received in step 210 (which belongs to only one zone). When the model received in step 210 comprises only one zone, step 240 may be omitted.

[0117] 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 weave composition is determined. For example, the initial cell determined in step 250 for the initial area determined in step 240 (or for the single area of ​​the model if it comprises only one area) can be the cell of the weave grid associated with the zero piece, i.e., the cell in which the zero piece is located.

[0118] By "weave composition" is meant a description of the weaving yarns (warp and weft) and how they are positioned relative to each other in the cell, or, equivalently, a set of data describing the weaving yarns and how they are positioned relative to each other in each cell of the weave grid. In particular, the data relates to the number of layers associated with each cell, the number of weft and warp yarns per layer, the spacing between layers, the spacing between weft and warp yarns, the number of weft (or warp) yarns between two consecutive warp (or weft) yarns, etc. This data can be represented as a 3D map, as in [Fig. 4], which shows some cross-sections of such a map.

[0119] Figure 4 thus represents a weaving grid and weaving compositions for cells of the weaving grid, according to several cross-sections. The weaving grid shown in Figure 4 comprises a plurality of cells 401a, 401b, 401c, 401d, 401e. In this figure, the X direction corresponds to that of the warp yarns 402a, 402b, 402c (represented with dashed lines) and the Y direction corresponds to that of the weft yarns 403a, 403b, 403c (represented with hatching).

[0120] When the current cell is the cell corresponding to the zero piece, step 260 (which corresponds to a step for determining the weave composition) can be omitted, because the weave composition of the initial cell was already determined in step 230. In step 270, it is checked whether all cells in the area under consideration have been populated (i.e., whether step 260, which determines the weave composition of a cell, has been implemented for all cells in the current area). If all cells have not yet been populated (step 275, arrow "N"), a new cell is considered (step 275), and the weave composition determination step (step 260) is implemented for this new cell. When all cells have been populated (step 270, arrow "O"), and if the model received in step 210 comprises a plurality of areas, it is checked in step 280 whether all areas 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 (step 250), and the weave composition for the cells of the new area is determined (steps 260, 270, and 275). When all areas of the model have been populated (step 280, arrow "O"), the population method is complete. It is then possible, for example, to graphically represent the 3D map of the part (step 290). Alternatively or in addition, step 290 can include representing successive cross-sections of the 3D map as "weave cards," which can be used as input data for the loom to produce the woven reinforcement of the part.

[0121] When the model comprises only one area, steps 280 and 285 can be omitted.

[0122] During step 275, the determination of the new cell is carried out from a predefined path of the weaving grid / intermediate weaving grid. An example of such a path is shown in [Fig. 5].

[0123] In the example in [Fig. 5], two intermediate weaving grids 502a and 502b are shown, corresponding respectively to two adjacent areas of the pattern. In this example, the intermediate weaving grid 502a is assumed to include the zero piece 503. The zero piece 503 divides 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 weave composition is determined. Then, the cells are filled (or “populated”) step by step along a predefined path. In the example of [Fig.5], this predefined path starts at part 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 the zero piece 503.

[0124] The three other quadrants 501b, 501c, 501d can be populated in a similar manner. For example, the second quadrant 501b can be populated by starting with cell 507 directly adjacent to part zero 503, then populating the cells step by step in a direction 508a opposite to the direction 504a of the first quadrant 501a, and going up the lines in the Y direction in a similar manner to the first quadrant 501a.

[0125] The four quadrants 501a, 501b, 501c, 501d can be populated successively or in parallel, provided that the zero part 503 has been populated.

[0126] When the four quadrants 501a, 501b, 501c, 501d have been populated, the loop of steps 260-270-275 of [Fig. 2] is completed for the current area, and the next area is selected if necessary (step 285 of [Fig. 2]). The next area can be selected as described previously for determining the weave grid 230.

[0127] Referring again to [Fig. 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 adjacent to a cell of the first already populated intermediate weaving grid 502a.

[0128] During the implementation of an iteration of step 260, the weave composition of the current cell is therefore determined. This determination is made based on the weave of the current area determined in step 230, as well as the warp and weft yarns of the current cell determined in step 230, so as to jointly determine the difference between the fiber volume fraction in the cell thus filled and the target fiber volume fraction, 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 required that the number of layers of the current cell be between: • the minimum number of layers in neighboring cells already filled, minus a first predetermined allowed variation; and • the maximum number of layers of neighboring cells already filled plus a second predetermined allowed variation.

[0129] In addition, if the predefined values ​​of the parameters relating to manufacturing constraints received in step 220 include a maximum or minimum number of layers, this number can be taken into account to determine the number of layers of the current cell in step 260.

[0130] In addition, rules relating to the number of layers can be predefined to determine when the number of layers in a cell should be reduced or increased relative to the number of layers in the cell filled in the previous step. These rules are generally defined by the textile department and are part of the manufacturing constraint parameters received in step 220. They may, in particular, concern constraints relating to alternating yarns or constraints on continuity in the number of layers.

[0131] The number of layers in the current cell can also be determined from the weave selected in step 230 for the area containing the current cell (current area). Indeed, depending on the type of part to be manufactured, certain weaving rules may be imposed, for example, only allowing yarn splitting 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, yarn splitting is not possible, and therefore the number of layers in the current cell must be the same as in the neighboring cells.

[0132] According to one example implementation, each cell can be modeled by a data matrix, each component of this matrix representing information about the yarn present in the portion of the cell corresponding to the matrix component (each component can, for example, take one of the following values: a first value indicating that there is no yarn in the portion of the cell considered, a second value indicating that there is a weft yarn in the portion of the cell considered, and a third value indicating that there is a warp yarn in the portion of the cell considered). Of course, other implementations are possible.For example, two matrices of the same size can be associated with each cell, one corresponding to the warp yarns and the other to the weft yarns. For each of the two matrices, the components can be equal to 0 if no yarn of the type in question is present in the corresponding regions, and to a value representing the yarn count used if a yarn of the type in question is present in the corresponding regions. According to another implementation example, a 3D representation of the woven piece can be represented by a 3D matrix containing cells, each cell representing a warp / weft intersection, in which it is indicated whether or not the warp yarn is caught by the weft yarn. This 3D matrix is ​​constructed from the model of the piece received in step 210 (e.g., thickness maps), the weaving grids, and the weave compositions determined in steps 230 to 280.

[0133] The weave compositions determined for cells in areas already populated and adjacent to cells in a new, unpopulated area can be used as input data to populate this new area. The same applies to the different layers of the model, where applicable.

[0134] The process in [Fig. 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 process cannot achieve complete filling of all cells while respecting manufacturing constraints. In this case, this weaving grid is discarded, and only the weaving grids for which all the cells of the model have been filled are retained. Furthermore, applying the process in parallel to several weaving grids makes it possible, at the end of the process, to determine "global" parameters for 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 overall parameters are closest to the manufacturing constraints.

[0135] The [Fig.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.

[0136] In these embodiments, the device includes a computer 600, comprising a memory 601 for storing instructions enabling the implementation of the process, predefined values ​​of parameters relating to manufacturing constraints, and temporary data for carrying out different steps of the processes described above.

[0137] The computer 600 further comprises a circuit 602. This circuit can be, for example, a processor capable of interpreting instructions in the form of a computer program, an electronic card whose steps of the process of the invention are described in silicon, or a programmable electronic chip such as an FPGA chip (for "Field-Programmable Gate Array" in English).

[0138] The computer 600 includes an input interface 403 for receiving the model of the part to be manufactured and predefined parameter values ​​relating to manufacturing constraints, and an output interface 604 for providing the weave map. 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 case of a computer in the form of a touch tablet, for example.

[0139] Furthermore, the functional diagram shown in [Fig. 2] is a typical example of a program in which certain instructions can be executed using the described device. As such, [Fig. 2] can be considered the flowchart of the general algorithm of a computer program within the meaning of the invention.

[0140] Of course, the present invention is not limited to the embodiments described above by way of example; it extends to other variants.

Claims

Demands

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

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

3. A method according to any 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 yarns (403a, 403b, 403c) and warp yarns (402a, 402b, 402c) and of a relative arrangement of the weft yarns (403a, 403b, 403c) and warp yarns (402a, 402b, 402c) in said each cell (401a, 401b, 401c, 401d, 401e) of the weaving grid.

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

5. A method according to any one of the preceding claims, wherein the second subset of parameters relating to manufacturing constraints of the part area 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 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.

6. A computer-implemented method for determining a car- weaving totography of a part to be manufactured in a woven composite material, comprising: - receive 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 (301a, 301b, 301c, 301d), successively determine weaving maps of said each zone by the method according to one of claims 1 to 5; in which the determination of the weave mapping of a current area is a function of the weave mapping of an area other than the 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.

7. A method according to claim 6, wherein the determination of the weave mapping for the current area comprises: - 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.

8. A method according to any one of the preceding claims, wherein the part to be manufactured is an aeronautical part.

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

10. Device for determining a weave map of an area (301a, 301b, 301c, 301d) of a part to be manufactured in a material woven composite, comprising: - an input interface to receive (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: • determine (230), from the representation of the part area and a first subset of values ​​from among the predefined values ​​received, a weaving grid of the part area, the weaving grid comprising a plurality of cells (401a, 401b, 401c, 401d, 401e); and • determine (260) successively, for each cell of the weaving grid, a respective weaving composition compatible with a second subset of values ​​from among the predefined values ​​received; in which the determination (260) 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 in which the weaving mapping of the piece area includes the cells of the weaving grid and the respective weaving compositions.

11. 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 devices according to claim 10, each device being configured to determine a weave map of a respective zone among the plurality of zones; in which the determination of the weave mapping of a current area is a function of the weave mapping of an area other than the 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.

12. A system for manufacturing a part from 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 determined weaving map of the piece.

13. Product computer program comprising instructions to implement the method according to any one of claims 1 to 9 when this program is executed by a processor.

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