Composite Turbomachine Blade Manufacturing via Preform Segmentation
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Solution Overview
Problem
The manufacturing of turbomachine blades made of composite materials faces challenges in producing and shaping textile preforms with the required secondary functions, particularly due to difficulties in producing and shaping fibrous reinforcements.
Innovation Solution
A method involving the separate production of two fibrous preforms, each supporting a limited number of functions, which are then assembled and co-densified to form a single-piece turbomachine blade, simplifying the manufacturing process and enhancing mechanical strength by distributing force extremes effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single textile preform is used to form the entire blade including all secondary functions, then the blade can be manufactured as a single piece, but the production and shaping of the textile preform becomes extremely difficult and complex
Solution Approach 1:
The blade is divided into two separate textile preforms: a first preform containing the blade root and tenon, and a second preform containing the blade platform and secondary functions. These preforms are manufactured separately using simpler textile structures, then assembled together to form the complete blade, avoiding the complexity of creating a single integrated preform
Solution Approach 2:
The tenon of the first preform is inserted into an internal housing within the second preform, creating a nested assembly where one preform is partially contained within the other. This nesting arrangement enables the final single-piece blade structure while allowing each preform to be manufactured independently with simpler textile architectures
2Adaptability or versatility
If multiple secondary functions are integrated into the blade from a single preform, then the blade structure becomes more complete, but the textile definition and shaping become significantly more difficult
Solution Approach 1:
Secondary functions such as platforms, cooling holes, and structural features are concentrated in the second preform rather than distributed throughout a single complex preform. This segmentation allows each preform to have a specialized, simpler textile structure that is easier to define and shape while still achieving integrated functionality in the final assembly
Solution Approach 2:
Different regions of the blade are assigned to different preforms based on their functional requirements. The first preform handles the blade root and tenon regions, while the second preform handles the blade platform and secondary function regions. This local specialization simplifies the textile definition for each preform while maintaining overall blade functionality
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 simplifies the manufacturing process and improves the mechanical properties of the blade by allowing easier shaping and assembly of preforms, enhancing the blade's mechanical strength and enabling its use in turbines or turbomachines.
Implementation Method 1
a first fibrous preform in a single piece, said first preform comprising a first part forming a blade root preform extended by a second part having a thickness less than the thickness of the first part, said second part forming a tenon preform
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
Method of manufacturing a turbomachine blade (100) made of composite material, comprising a fibrous reinforcement consolidated by a matrix, the method involving: • - creating a multilayer woven fabric so as to obtain a first fibrous preform (1) in a single piece, said first preform (1) comprising a first part (2) forming the blade root preform and extended by a second part (3) having a thickness smaller than the thickness of the first part (2), said second part (3) forming a stub preform, • - creating a multilayer woven fabric so as to obtain a second fibrous preform (4; 14; 14') in a single piece, said second preform (4; 14; 14') comprising a first part (5; 15; 15') formed of two skins (5a; 5b; 15a; 15b; 15'a; 15'b) between them delimiting an internal housing (6), said first part (5; 15; 15') forming a blade air foil preform, and at least a second part (7; 17; 17') extending from the external surface of said skins (5a; 5b; 15a; 15b; 15'a; 15'b), said at least second part (7; 17; 17') forming a platform preform, • - the assembly of the first preform (1) in the consolidated or non-preconsolidated state with the second form (4; 14; 14') in the non-consolidated state by engagement of the second part (3) of the first preform (1) into the internal housing (6) of the first part (5; 15; 15') of the second preform (4; 14; 14'), and • - the codensification of the first (1) and second (4; 14; 14') preforms thus assembled in order to obtain a turbomachine blade (100).