Method for manufacturing multi-axial three-dimensional woven structure composite material blade preform and apparatus

Abstract

A method for manufacturing a multi-axial three-dimensional woven structure composite material blade preform and an apparatus. The method comprises the following specific steps: (1) arranging 0° warp yarns; (2) introducing 90° weft yarns; (3) introducing +-θ° bias yarns; (4) compacting fabric; (5) repeating steps (1)-(4) until a target thickness of the fabric is obtained; and (6) introducing Z-direction yarns. Compared with a conventional three-dimensional woven structure which is only arranged in three directions, i.e., X, Y, and Z axes, due to the introduction of the bias yarns, the design performance of a composite material blade is improved, the elastic performance of the composite material is improved by means of the introduction of the bias yarns, and the anti-fatigue bearing capacity under the vibration load is improved.

Description

Preparation method and equipment for multi-axial three-dimensional woven structure composite blade preform Technical Field

[0001] The present invention relates to the preparation of multi-axial three-dimensional woven blades, and in particular to a method and equipment for preparing a multi-axial three-dimensional woven structure composite material blade preform. Background Art

[0002] Currently, composite blades are mostly made of laminated composites or conventional three-dimensional woven composites. Prepreg layup is the most mature process for forming resin-based composite blades, and the resulting blades have excellent toughness and damage resistance. However, the poor interlaminar performance of two-dimensional laminated composites is a key weakness. In the field of three-dimensional weaving, research has been conducted to achieve weaving blade preforms with variable thickness in both the longitudinal and transverse directions by adding yarn pads. However, conventional three-dimensional weaving only arranges fibers in the X, Y, and Z directions, resulting in insufficient designability and limited in-plane shear performance of the composite material.

[0003] Therefore, a new technical solution is needed to solve the above problems. Summary of the Invention

[0004] Purpose of the invention: Based on the above problems and in response to the problems existing in the prior art, the present invention provides a method and equipment for preparing a multi-axial three-dimensional woven structure composite blade preform. The multi-axial blade preform is used to improve the designability and in-plane shear performance of the blade composite preform.

[0005] Technical solution: The present invention provides a method for preparing a multi-axial three-dimensional woven structure composite blade preform, comprising the following steps:

[0006] (1) Before weaving begins, the steel bar shaft is inserted into the array of guide rods to fix the upper end of the base plate;

[0007] (2) The weaving needle moves between the guide rods through the X-axis and Y-axis motions, and the 0° warp yarn and the 90° weft yarn are introduced in sequence;

[0008] (3) Control the angle of the weaving needle and the running trajectory when turning to introduce the bias yarn. The angle between the bias yarn and the 0° warp yarn is ±θ°;

[0009] (4) compacting the fabric by a compacting plate;

[0010] (5) After the weaving needle moves upward along the Z axis for a certain distance, steps (1) to (4) are repeated until the target thickness of the fabric is obtained;

[0011] (6) After taking out the fabric, replace the yarn and introduce the Z-direction yarn.

[0012] Furthermore, in step (5), the thickness of the blade preform is varied, and the total number of warp, weft and bias yarn layers needs to be calculated according to the fabric structure design requirements. Where d is the thickness of the fabric, d1, d2, and d3 represent the thickness of the warp, weft, and bias yarns, respectively.

[0013] The present invention also provides a technical solution for a multi-axial three-dimensional woven blade preform prepared by the above-mentioned preparation method, wherein the preform contains 0° warp yarn, 90° weft yarn, +θ° bias yarn, and -θ° bias yarn. From the cross-section of the preform, the preform is composed of multiple unit layers stacked up and down, and each unit layer is composed of 0° warp yarn, +θ° bias yarn, -θ° bias yarn and 90° weft yarn arranged in sequence.

[0014] The present invention also provides equipment for preparing the above-mentioned multi-axial three-dimensional woven structure composite material blade preform, including a frame, a steel bar C1 axis, a steel bar C2 axis, a guide rod, a weaving needle, a first turntable, a second turntable, and a lifting axis; the steel bar C1 axis and the steel bar C2 axis are inserted between the guide rods, the weaving needle is used to carry the yarn along the X axis, Y axis, and Z axis, and shuttle between the guide rods to form a flexible fabric, the first turntable is used to control the direction of the weaving needle, the second turntable is used to control the angle of the weaving needle, and the lifting axis is used to control the Z-direction movement of the compacting plate.

[0015] Furthermore, the guide rod is located in the middle position of the lower part of the frame, and the X-axis and Y-axis are located above the frame. The X-axis includes two parallel axes, and the two ends of the Y-axis are respectively installed on the two X-axes through X-axis sliders, and the Y-axis moves along the length direction of the X-axis through the X-axis slider; the Z-axis is installed on the Y-axis through the Y-axis slider, and the Z-axis moves along the length direction of the Y-axis through the Y-axis slider; the first turntable and the second turntable are installed on the Z-axis through the Z-axis slider, and the first turntable and the second turntable move up and down along the length direction of the Z-axis through the Z-axis slider.

[0016] Furthermore, the length direction of the steel bar C1 is parallel to the length direction of the X axis, and the length direction of the steel bar C2 is parallel to the length direction of the Y axis.

[0017] Beneficial effects: Compared with the existing technology, the present invention is based on a multi-axial three-dimensional woven structure composite blade preform preparation process, which introduces bias yarn by controlling the angle and trajectory of the weaving needle's movement in the guide, and controls the thickness of the yarn at each position, and has the characteristics of high degree of cleanliness and strong designability; the present invention is based on a multi-axial three-dimensional woven structure composite blade preform preparation equipment, which improves the level of automation in the preform production process, and can effectively reduce the processing deformation and fiber bundle damage after the preform is weaved or composite formed, and ultimately ensures the dense molding and mechanical properties of the composite material. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG1 is a perspective view of an apparatus for preparing a multi-axial three-dimensional woven structure composite material blade preform according to the present invention;

[0019] FIG2 is a partial enlarged view of the positions of the first turntable and the second turntable in the equipment for preparing a multi-axial three-dimensional woven structure composite material blade preform;

[0020] Figure 3 shows the direction of yarn movement.

[0021] FIG4 is a structural diagram of the prepared blade preform. DETAILED DESCRIPTION

[0022] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] As shown in Figures 1 and 2, the present invention provides an apparatus for producing a preform for a multi-axial, three-dimensional woven composite blade structure. The apparatus comprises a frame 03, a steel bar C1 axis 01, a steel bar C2 axis 13, guide rods 11, weaving needles 09, a first turntable 07, a second turntable 08, a lifting shaft 02, and a base plate 12. Guide rods 11 are arranged in rows and extend upward from bottom to top on base plate 12. The length of steel bar C1 axis 01 is parallel to the X-axis, and the length of steel bar C2 axis 13 is parallel to the Y-axis. The steel bar C1 axis 01 and the steel bar C2 axis 13 are inserted between the guide rods 11. The weaving needle 09 is used to carry the yarn along the X-axis 05, Y-axis 06, and Z-axis 04, and shuttle between the guide rods 11 to form a flexible fabric. The first turntable 07 is used to control the direction of the weaving needle 09, the second turntable 08 is used to control the angle of the weaving needle 09, and the lifting axis 02 is used to control the Z-direction movement of the compacting plate 10. Among them, the guide rod 11 is located in the middle position of the lower part of the frame 03, the X-axis 05 and the Y-axis 06 are located above the frame 03, the X-axis 05 includes two parallel to each other, and the two ends of the Y-axis 06 are respectively installed on the two X-axes through the X-axis slider, and the Y-axis 06 moves along the length direction of the X-axis through the X-axis slider; the Z-axis 04 is installed on the Y-axis 06 through the Y-axis slider, and the Z-axis 04 moves along the length direction of the Y-axis through the Y-axis slider; the first turntable 07 and the second turntable 08 are installed on the Z-axis 04 through the Z-axis slider, and the first turntable 07 and the second turntable 08 move up and down along the length direction of the Z-axis through the Z-axis slider.

[0024] The method for preparing a multi-axial three-dimensional woven structure composite material blade preform using the above equipment includes the following steps:

[0025] (1) Before weaving begins, the steel bar shaft is inserted into the array of guide rods 11 and the upper end of the base plate 12 is fixed.

[0026] (2) The weaving needle 09 moves between the guide rods by moving the X-axis 05 and the Y-axis 06, and the 0° warp yarn and the 90° weft yarn are introduced in sequence.

[0027] (3) Control the angle of the weaving needle and the running trajectory when turning is required to introduce the bias yarn, and the angle between the bias yarn and the 0° warp yarn is ±θ°;

[0028] (4) compacting the fabric by a compacting plate;

[0029] (5) After the weaving needle (09) moves upward along the Z axis for a certain distance, steps (1) to (4) are repeated until the target thickness of the fabric is obtained;

[0030] (6) After taking out the fabric, replace the yarn and introduce the Z-direction yarn.

[0031] In steps (2)-(3), the rotation of the second turntable 08 can control the angle of the weaving needle 09, which can form a certain angle with the guide rod to better output the yarn and reduce yarn fuzzing. The rotation of the first turntable 07 can control the needle direction of the weaving needle 09 and control the yarn to move between the guide rods as shown in Figure 3, thereby realizing automatic implantation of yarns at 0°, 90°, and ±θ°.

[0032] The multi-axial three-dimensional woven blade preform prepared by the above preparation method contains 0° warp yarn, 90° weft yarn, +θ° bias yarn, and -θ° bias yarn. From the cross-section of the preform, the preform is composed of multiple unit layers stacked up and down, and each unit layer is composed of 0° warp yarn, +θ° bias yarn, -θ° bias yarn and 90° weft yarn arranged in sequence. The technical principle of the blade preform prepared by the above method is: the adjustable blade will be subjected to the centrifugal force F during operation. y0 , the resistance F that opposes the rotation direction z0 , thrust F generated by the blade x0 When the adjustable blades rotate through an angle α, the engine achieves maximum efficiency at all flow rates. The angle of attack of the adjustable guide vanes—the angle between the blades and the airflow—increases, increasing both resistance and thrust. The angle of the fabric's diagonal yarns enhances strength in both the X and Z axes, and this strength enhancement can be designed to outweigh the thrust resistance experienced by the blades, ensuring blade strength.

[0033] In summary, the multi-axial three-dimensional woven blade of the present invention contains 0° yarn, 90° yarn, +θ° yarn, -θ° yarn. From the perspective of the preform cross section, the preform is composed of multiple unit layers stacked up and down, and each unit layer is composed of warp yarn, + bias yarn, - bias yarn and weft yarn arranged in sequence. The angle of the bias yarn can be designed according to the needs of preform preparation to improve the shear performance of the composite material; the warp yarn is located in the 0° direction, and the weft yarn is located in the 90° direction, respectively providing strength for the two axial directions of the composite material. When preparing a multi-axial three-dimensional woven preform, if it is necessary to prepare a preform with variable thickness, the number of unit layers in the cross section of the preform can be directly reduced, or it can be achieved by reducing the number of yarn layers, warp density and weft density in the unit layer. At the same time, this method has the advantages of simple operation, high production efficiency, stable process, etc., and can meet the high-performance and low-cost manufacturing requirements of high-performance composite blades.

[0034] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions based on the principles of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A method for preparing a multi-axial three-dimensional woven structure composite blade preform, characterized in that: The following steps are involved: (1) Before weaving begins, the steel bar shafts (01, 13) are inserted into the array of guide rods (11) to fix the upper end of the bottom plate (12); (2) the weaving needle (09) moves between the guide rods by moving the X-axis (05) and the Y-axis (06), and the 0° warp yarn and the 90° weft yarn are introduced in sequence; (3) Control the angle of the weaving needle and the running trajectory when turning to introduce the bias yarn, and the angle between the bias yarn and the 0° warp yarn is ±θ°; (4) compacting the fabric by a compacting plate; (5) After the weaving needle (09) moves upward along the Z axis for a certain distance, steps (1) to (4) are repeated until the target thickness of the fabric is obtained; (6) After taking out the fabric, replace the yarn and introduce the Z-direction yarn.

2. The method for preparing a multi-axial three-dimensional woven structure composite blade preform according to claim 1, characterized in that: In step (5), the variable thickness preparation of the blade preform needs to calculate the total number of warp, weft and bias yarn layers according to the fabric structure design requirements. Where d is the thickness of the fabric, d1, d2, and d3 represent the thickness of the warp, weft, and bias yarns, respectively.

3. An equipment for preparing a multi-axial three-dimensional woven structure composite material blade preform as claimed in claim 1 or 2, characterized in that: The invention comprises a frame (03), a steel bar C1 axis (01), a steel bar C2 axis (13), a guide rod (11), a weaving needle (09), a first turntable (07), a second turntable (08), and a lifting axis (02); the steel bar C1 axis (01) and the steel bar C2 axis (13) are inserted between the guide rods (11); the weaving needle (09) is used to carry the yarn and move along the X axis (05), the Y axis (06), and the Z axis (04), and shuttle between the guide rods (11) to form a flexible fabric; the first turntable (07) is used to control the direction of the weaving needle (09); the second turntable (08) is used to control the angle of the weaving needle (09); and the lifting axis (02) is used to control the Z-direction movement of the compacting plate (10).

4. The device according to claim 3, characterized in that: The guide rod (11) is located in the middle of the lower part of the frame (03); the X-axis (05) and the Y-axis (06) are located above the frame (03); the X-axis (05) includes two parallel axes; the two ends of the Y-axis (06) are respectively installed on the two X-axes through X-axis sliders; the Y-axis (06) moves along the length direction of the X-axis through the X-axis slider; the Z-axis (04) is installed on the Y-axis (06) through the Y-axis slider, and the Z-axis (04) moves along the length direction of the Y-axis through the Y-axis slider; the first turntable (07) and the second turntable (08) are installed on the Z-axis (04) through the Z-axis slider, and the first turntable (07) and the second turntable (08) move up and down along the length direction of the Z-axis through the Z-axis slider.

5. The device according to claim 4, characterized in that: The length direction of the steel bar C1 axis (01) is parallel to the length direction of the X axis, and the length direction of the steel bar C2 axis (13) is parallel to the length direction of the Y axis.

6. A multi-axial three-dimensional woven blade preform prepared by the preparation method according to claim 1 or 2, characterized in that: The preform contains 0° warp yarn, 90° weft yarn, +θ° bias yarn, and -θ° bias yarn. From the cross-section of the preform, the preform is composed of multiple unit layers stacked up and down, and each unit layer is composed of 0° warp yarn, +θ° bias yarn, -θ° bias yarn and 90° weft yarn arranged in sequence.

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