Composite Cylindrical Case Fiber Orientation
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Solution Overview
Problem
The existing manufacturing methods for fan cases using composite materials with reinforcing fibers and thermosetting resin struggle to achieve sufficient strength and rigidity, particularly at the annular outward flange, due to fiber meandering and wrinkling issues during molding, which compromises the overall structural integrity.
Innovation Solution
A cylindrical case design featuring a case main body with alternately laminated biaxial fabric layers and roving layers, along with triaxial fabric layers for the groove wall, ensuring reinforcing fibers are oriented between ±15-75° to the axial direction, and using a manufacturing method that includes biaxial, roving, and triaxial fabric layer formation steps, followed by heating to cure the thermosetting resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing fibers having an inclination angle of 0-10° to the circumferential direction are included to secure sufficient strength and rigidity, then the strength and rigidity of the laminate is improved, but the flexibility of the fabric is impaired causing wrinkling or fiber meandering during molding
Solution Approach 1:
The patent changes the orientation angle parameter of reinforcing fibers from the conventional 0-10° to ±15-75° relative to the axial direction. This parameter change allows the fabric to maintain flexibility during molding while achieving sufficient strength and rigidity in the cured composite structure, thereby eliminating wrinkling and fiber meandering issues.
Solution Approach 2:
The patent uses a composite material system consisting of reinforcing fibers (with optimized orientation), a thermosetting resin matrix, and optionally a core material. This composite structure enables the laminate to achieve both flexibility during molding and high strength/rigidity after curing, resolving the contradiction between manufacturability and structural performance.
2Strength
If reinforcing fibers having an inclination angle of ±0-75° to the circumferential direction are included to secure sufficient strength and rigidity, then the strength and rigidity of the fan case is improved, but the flexibility of the fabric is impaired causing wrinkling or fiber meandering in the outward flange during molding
Solution Approach 1:
The patent optimizes the orientation angle parameter of reinforcing fibers to ±15-75° relative to the axial direction, which balances the flexibility needed for molding the outward flange without defects and the strength/rigidity required for the final fan case structure.
Solution Approach 2:
The patent applies different fiber orientation configurations to different regions of the fan case. The reinforcing fibers are arranged at ±15-75° to the axial direction in the case main body, while the outward flange uses configurations that maintain flexibility during molding, allowing each region to have optimal properties for its specific function.
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 approach enhances the strength and rigidity of the entire case while preventing fiber meandering and wrinkling, allowing for effective load-bearing capabilities and labor-saving automatic molding processes.
Implementation Method 1
this laminate is heated to cure the thermosetting resin with which the laminate is pre-impregnated
Data Source
AI summary
A cylindrical case includes a case main body, and a groove disposed annularly at one end of the case main body. A peripheral wall of the case main body is formed by alternately laminating a biaxial fabric layer, which includes a biaxial fabric of a non-crimp structure composed of reinforcing fiber bands having an orientation angle of ±45°, and a roving layer. A groove wall of the groove is formed by alternately laminating the biaxial fabric layer, which continues to the case main body side, and a triaxial fabric layer, which includes a triaxial fabric of a non-crimp structure composed of reinforcing fiber bands having an orientation angle of ±45° and a reinforcing fiber band having an orientation angle of 0°.