Composite Fan Blade Manufacturing via Continuous Ply Folding
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Solution Overview
Problem
The existing methods for manufacturing composite fan blades are time-consuming due to the need for multiple plies and extensive lay-up processes, particularly with automated fibre placement (AFP), which increases the time spent on cutting, positioning, and secondary operations.
Innovation Solution
The method involves laying up continuous plies on a preform tool, folding them around a core to create a consolidated preform, and then applying pressure and heat to cure the composite fan blade, reducing the number of operations and speeding up the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple plies are used to manufacture composite fan blade, then the mechanical strength and structural integrity are improved, but the lay-up time and manufacturing complexity increase significantly
Solution Approach 1:
Multiple separate plies are combined into a single preformed laminate structure before being placed in the autoclave. This merging of multiple layers into one pre-assembled unit reduces the number of individual lay-up operations required while maintaining the structural integrity and mechanical strength of the composite fan blade.
Solution Approach 2:
The laminate is pre-formed on a suction surface tool before autoclave processing. This preliminary action of assembling multiple plies into a complete laminate structure in advance eliminates the need for time-consuming sequential lay-up operations during the main manufacturing process, significantly reducing overall manufacturing time.
2Manufacturing precision
If automated fibre placement is used to apply multiple tows with different orientations, then the manufacturing precision and fibre orientation control are improved, but the number of cuts and positioning operations increase
Solution Approach 1:
Multiple tows with different fibre orientations are merged into a single integrated laminate structure during the pre-forming stage. This approach maintains the precision of fibre orientation control while reducing the number of separate placement and cutting operations required during automated fibre placement.
Solution Approach 2:
The manufacturing process is segmented into two distinct stages: pre-forming of the laminate structure and subsequent autoclave curing. This segmentation allows complex multi-orientation fibre assemblies to be prepared in advance with high precision, then transferred as a complete unit to the autoclave, eliminating repeated positioning and cutting operations.
3Productivity
If the number of plies is reduced to speed up the process, then the lay-up time is decreased, but the structural integrity and mechanical properties may be compromised
Solution Approach 1:
Multiple plies are merged into a single preformed laminate that contains all necessary layers with appropriate orientations. This merging allows the complete multi-ply structure to be handled as one unit during transfer to the autoclave, maintaining full structural integrity while speeding up the lay-up process by eliminating sequential placement of individual 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 approach significantly reduces the lay-up time by minimizing the number of cuts and operations required, enhancing the efficiency of the composite fan blade manufacturing process.
Implementation Method 1
the plies are laid-up manually or automatically on a preform tool shaped to the finished blade suction surface to produce a fan blade preform. Once all of the plies have been laid up, the preform is transferred into a tool and cured in an autoclave to the final shape.
Data Source
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AI summary
A method of manufacturing a composite fan blade (40) with an outer part (58) and a core (60) comprises laying up a plurality of continuous plies (62) to achieve a stack (81), placing the core (60) on a central portion (92) of the stack (81) of continuous plies (62) to achieve an unfolded preform (83); folding the continuous plies (62) about the core (60), such that the central portion (92) of the stack (81) folds about the core (60) and a first portion (88) is superimposed to a second portion (90), to achieve a folded preform (85); applying pressure to the folded preform (85) to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade (40).