Blade Root Preforms From Contour-Woven Fibrous Textures
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Solution Overview
Problem
Existing methods for manufacturing turboprop propeller parts and turbomachine blades face issues with fiber orientation deviations and mechanical performance due to limitations in braiding techniques, particularly in areas of thickness variation, requiring manual draping and complex pre-compaction operations.
Innovation Solution
A method using contour weaving with a non-cylindrical take-up mandrel to produce a fibrous texture that matches the substrate shape without deformation, combined with co-winding a multiaxial sheet to achieve desired fiber orientations and improve mechanical strength, allowing for high production rates and controlled costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If braiding technique is used to manufacture propeller parts with thickness variation, then production can be automated, but fiber orientation deviations occur reducing mechanical performance
Solution Approach 1:
The invention divides the manufacturing process into two independent stages: (1) weaving the fibrous texture on a cylindrical mandrel, and (2) winding the woven texture onto the final substrate. This segmentation allows each stage to be optimized independently - the weaving stage ensures precise fiber orientations in a controlled environment, while the winding stage adapts to the complex substrate geometry, thereby resolving the contradiction between automation and precision.
Solution Approach 2:
The woven fibrous texture acts as an intermediary between the braiding machine and the final substrate. Instead of directly braiding on the complex-shaped substrate, the invention first creates a standardized woven texture that can be precisely controlled, then winds this intermediary product onto the substrate. This intermediary approach maintains automation while ensuring fiber orientation precision.
2Quantity of substance
If manual draping of unidirectional fiber layers is used during braiding to increase fiber quantity, then fiber quantity increases, but process complexity and manufacturing time increase
Solution Approach 1:
The invention enables continuous production by weaving the fibrous texture continuously on the cylindrical mandrel and then continuously winding it onto the substrate. This eliminates the need for intermittent manual draping operations, maintaining continuous automated production while achieving the desired fiber quantity through optimized winding parameters and multiple wrapping layers.
3Manufacturing precision
If intermediate pre-compaction operations are performed to limit preform expansion, then dimensional control improves, but manufacturing time and process complexity increase
Solution Approach 1:
The invention performs preliminary shaping during the weaving stage on the cylindrical mandrel, creating a pre-formed texture that anticipates the final substrate geometry. This preliminary action reduces the need for subsequent pre-compaction operations, as the woven texture is already pre-shaped to match the substrate contours, thereby maintaining dimensional control while reducing manufacturing time.
4Manufacturing precision
If contour weaving with non-cylindrical take-up mandrel is used to match substrate shape, then fiber orientation precision improves, but device complexity increases
Solution Approach 1:
The invention applies local quality by using a cylindrical mandrel for the weaving process (simple geometry) while achieving complex local fiber orientations through the winding operation. The cylindrical mandrel provides a uniform, simple weaving environment, and the subsequent winding onto the complex substrate creates the required local fiber orientation variations, thereby achieving precision without mandrel complexity.
Data Source
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AI summary
The invention relates to a method for producing a fibrous preform for part of a blade or propeller of a turbomachine, comprising at least one attachment root extended by a portion for mounting an airfoil, the method comprising at least the winding of a fibrous weave (12) obtained by weaving to shape on a substrate of variable cross section having at least a first region of extra thickness in the shape of the attachment root and a second region in the shape of the portion for mounting an airfoil.