Compacting Block for Fan Casing Mold Thickness Control
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Solution Overview
Problem
The existing injection mold technology for manufacturing gas turbine blower housings with composite materials faces significant variability in the thickness of the final part due to interactions between angular sectors and the mold, leading to inconsistent resin injection and machining challenges.
Innovation Solution
The proposed mold design features a compacting hold positioned on one of the side flanges of the mandrel, which covers the top of an external strap of the housing, improving the repeatability and precision of the mold's positioning and reducing the variability of the preform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compacting wedges are positioned between the angular sectors and the fiber preform, then compaction force is applied to maintain preform thickness, but positioning variability increases due to interactions between the wedge and sectors
Solution Approach 1:
The patent introduces a positioning element that acts as an intermediary between the compacting wedge and the angular sector. This intermediary component provides a stable reference surface for the wedge, eliminating the variability in positioning that occurred when the wedge directly contacted the sector. The intermediary ensures consistent wedge position across multiple manufacturing cycles, thereby improving both positioning reliability and thickness uniformity.
Solution Approach 2:
The positioning element is pre-installed on the mandrel before the compacting wedge is positioned. This preliminary arrangement establishes a fixed reference framework that guides the wedge into the correct position. By preparing the positioning infrastructure in advance, the system eliminates the need for complex real-time adjustments and ensures repeatable wedge positioning, directly addressing the reliability issue.
2Reliability
If angular sectors are used to close the mold, then the mold is sealed to contain resin, but thickness variability is introduced at the flange areas
Solution Approach 1:
The patent applies different functional characteristics to different regions of the mold assembly. The angular sectors provide sealing functionality in the radial direction, while the positioning element provides precision positioning functionality at the flange areas. This local differentiation allows each component to optimize its specific function without compromising the other, maintaining both sealing effectiveness and thickness consistency.
Solution Approach 2:
The mold closing system is divided into functionally independent components: the angular sectors handle sealing, while the positioning element handles precision positioning at the flanges. This segmentation allows each component to be optimized for its specific function. The positioning element can be precisely manufactured and positioned independently, ensuring flange thickness consistency without affecting the sealing capability of the angular sectors.
3Productivity
If resin is injected into the mold, then the composite casing is formed, but resin quantity varies due to thickness variability in the preform
Solution Approach 1:
The patent employs a resin injection system that utilizes fluid dynamics to control resin flow and distribution. By maintaining uniform preform thickness through the positioning element, the resin injection process achieves consistent resin quantity distribution. The hydraulic system can precisely control injection pressure and flow rate, ensuring that resin is distributed uniformly throughout the mold cavity, thereby improving both productivity and resin quantity control.
Data Source
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AI summary
Mould (300) for use in the manufacture of a gas turbine fan casing made of composite material comprising: