Composite Turbomachine Casing Fiber Placement Precision
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Solution Overview
Problem
Existing methods for manufacturing composite casings for turbomachines face challenges in precision fiber placement, geometric constraints, and limited precision, especially when dealing with an increasing number of component parts and complex geometries.
Innovation Solution
A method involving automatic fiber placement of carbon fibers on a concave form, followed by laying a glass-fiber ply on a convex form, transferring the preform onto the convex form, and curing the stack to form a composite casing, which includes machining and assembling half-shells, while maintaining precision and accommodating inserts and mechanical interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple component parts are used to create the composite casing, then the adaptability and precision of fiber placement improve, but the geometric constraints and complexity of the draping operation increase
Solution Approach 1:
The composite casing is divided into multiple component parts (first component part with carbon fibers on concave form, second component part with glass fibers on convex form). This segmentation allows each part to be manufactured independently with optimized fiber placement, improving precision while managing complexity through modular assembly.
Solution Approach 2:
A resin matrix acts as an intermediary material that bonds the carbon fiber component and glass fiber component together. This intermediary enables the assembly of multiple precision-manufactured parts into a unified structure, maintaining overall precision while allowing complex geometries to be achieved through controlled joining.
2Adaptability or versatility
If the number of component parts increases to improve precision, then fiber orientation adaptability improves, but the simplicity of manufacture decreases
Solution Approach 1:
Different fiber orientations and materials are segregated into separate component parts manufactured on different forms (concave and convex). This allows each component to be optimized for specific fiber orientations independently, improving adaptability while maintaining manufacturing simplicity through standardized processes applied to each segment.
Solution Approach 2:
The patent uses both concave and convex forms for manufacturing different component parts, inverting the traditional single-form approach. This inversion allows each component to be manufactured on the form type best suited for its specific geometry and fiber placement requirements, improving adaptability while keeping each manufacturing step simple and controlled.
3Manufacturing precision
If automatic fiber placement is used to improve precision, then fiber positioning accuracy improves, but the device complexity and cost increase
Solution Approach 1:
The automatic fiber placement process is applied separately to each component part on its dedicated form (concave or convex). This segmentation allows the use of automated systems for high-precision work while keeping each automated operation focused and manageable, reducing overall system complexity compared to a single complex automated system.
Solution Approach 2:
The fiber reinforcement structures are pre-formed on the concave and convex forms before final assembly. This preliminary action allows automatic placement to focus on precise positioning rather than also managing complex assembly operations, improving positioning accuracy while managing device complexity through staged manufacturing.
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 enhances precision and adaptability in fiber orientation, allowing the casing to withstand mechanical interfaces and machining processes, while maintaining precision even with an increasing number of components, and is economical, reliable, and easy to inspect.
Implementation Method 1
solidifying the 360° sheet and the segments together
Data Source
AI summary
A method for manufacturing a curved composite casing for a turbomachine, notably for a low-pressure compressor of an aircraft turbojet engine, includes the following sequence of steps: (a) draping a preform by automatic placement of carbon fibres on a concave form, referred to as a female form; (b) laying a glass-fibre ply on a convex form, referred to as a male form; (c) transferring the preform onto the convex form, covering the glass-fibre ply on the convex form. Step (b) laying includes a phase (α) of laying a metal strip and/or an epoxy profile on the convex form, then a phase (β) of covering the metal strip with the glass-fibre ply.