Composite Blade Layup and Machining to Reduce Ply Distortion
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Solution Overview
Problem
The manufacturing of composite blades for gas turbine engines faces challenges such as material waste due to excessive material volume in the root section during the cure cycle, ply distortion leading to undesired undulations in the laminate architecture, and inefficiencies in the use of filler plies.
Innovation Solution
A method involving the laying up of pre-impregnated composite material to form a pre-impregnated composite structure with two blade bodies positioned in a predetermined orientation, followed by vacuum bagging and consolidation to form a fiber-reinforced composite structure, and subsequent machining to create individual blades, which reduces material waste and enhances laminate quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a large volume of material is used in the root section during manufacturing, then ply distortion is prevented during the cure cycle, but significant material waste occurs
Solution Approach 1:
The blade manufacturing process is segmented into two distinct phases: (1) consolidation of the pre-preg blade structure with minimal root section material, and (2) subsequent autoclave curing. This segmentation allows the root section to be sufficiently supported during consolidation without requiring excessive material that would later be wasted, as the autoclave provides additional pressure support during curing.
Solution Approach 2:
The root section is preliminarily constructed with just enough material to prevent ply distortion during the consolidation phase, rather than using excessive material from the outset. This preliminary action with optimized material volume reduces waste while still achieving the necessary structural stability, with the understanding that additional support will be provided during the subsequent autoclave curing phase.
2Shape
If filler plies are used to build up airfoil geometry, then part of the geometry is constructed, but undesired undulations in the laminate architecture are generated
Solution Approach 1:
The function of building up airfoil geometry is extracted from the filler plies and assigned to a separate tooling process. The filler plies are removed from the laminate stack before curing, and the airfoil geometry is subsequently built up using traditional tooling methods, thereby eliminating the undulations that would otherwise be introduced by filler plies while still achieving the desired geometry.
Solution Approach 2:
The manufacturing process is segmented to separate the structural consolidation phase (where filler plies would be problematic) from the geometry formation phase. By removing filler plies before curing and using traditional tooling for geometry buildup, the process eliminates the source of undulations while maintaining the ability to construct the airfoil shape.
3Productivity
If traditional manufacturing methods are used, then blades are produced, but significant material waste and laminate defects occur
Solution Approach 1:
The manufacturing process is segmented into consolidation and curing phases, allowing optimization of material usage in each phase. The root section uses minimal material during consolidation, reducing waste, while the autoclave curing phase provides necessary pressure support without requiring additional material in the root section.
Solution Approach 2:
Filler plies are extracted from the laminate stack before curing, eliminating the source of undulations and material waste. The airfoil geometry function is extracted and performed separately using traditional tooling methods, allowing for precise geometry formation without the drawbacks of filler plies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces material waste, balances pressure during the cure cycle, and improves laminate quality by aligning ply directions and optimizing pressure distribution, resulting in efficient and precise blade manufacturing.
Implementation Method 1
vacuum bagging the pre-impregnated composite structure between a first pressure plate and a second pressure plate
Implementation Method 2
consolidating and curing the pre-impregnated composite structure to form a fiber-reinforced composite structure
Data Source
AI summary
A method of manufacturing composite blades comprises: laying up a pre-impregnated composite material to form a pre-impregnated composite structure; vacuum bagging the pre-impregnated composite structure between a first pressure plate and a second pressure plate; consolidating and curing the pre-impregnated composite structure to form a fiber-reinforced composite structure; and machining an overlap portion of the fiber-reinforced composite structure to form a first fiber-reinforced composite blade and a second fiber-reinforced composite blade.