Composite Fan Casing Flange Formation for Blade-Off Containment
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Solution Overview
Problem
Conventional methods for manufacturing composite fan casings with integral flanges struggle to meet design tolerances, compromising the ability of the composite material to contain fan blades during a blade-off event in gas turbine engines.
Innovation Solution
A method and system that utilize a tool with a flange-forming block and controlled transitions to ensure the flange radius conforms to design tolerances, involving a deposition configuration, an intermediate configuration, and a flange-forming configuration to support the composite pre-form without damage, allowing for vacuum consolidation and thermal adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used to form the flange of a composite fan casing, then the manufacturing process is simpler, but the flange cannot meet required design tolerances and may compromise the ability to contain blades during a blade-off event
Solution Approach 1:
The forming system is divided into multiple independent forming elements (first forming element, second forming element, third forming element) that can be positioned and actuated separately. Each element contributes to forming a specific portion of the flange, allowing precise control over the flange radius and surface transition while maintaining overall system manageability.
Solution Approach 2:
The forming elements are designed to be movable rather than fixed, allowing dynamic adjustment during the forming process. The forming elements can be actuated to apply controlled forces at specific stages of the forming operation, enabling the composite pre-form to be shaped into the required flange geometry with precise tolerance control.
2Reliability
If the flange is formed with high precision to meet design tolerances, then the ability to contain blades during blade-off events is improved, but the manufacturing process becomes more complex and difficult to control
Solution Approach 1:
The composite pre-form is prepared with a preliminary configuration that includes a second portion extending beyond the first portion. This preliminary arrangement of the pre-form is designed to work in conjunction with the forming elements, allowing the flange to be formed through a controlled sequence of actions that maintains reliability while managing process complexity.
Solution Approach 2:
The forming elements serve as intermediaries between the composite pre-form and the final flange geometry. These elements provide controlled interaction points that transfer forces systematically to the pre-form, enabling precise flange formation without requiring overly complex direct control mechanisms.
3Manufacturing precision
If a complex forming system is used to achieve precise flange geometry, then manufacturing precision is improved, but the ease of manufacture decreases
Solution Approach 1:
Different portions of the forming system are optimized for specific local functions. The first forming element addresses the first portion of the flange, the second forming element addresses the second portion, and the third forming element addresses the third portion. This localized approach allows each element to be simple and easy to operate while collectively achieving the required overall precision and smooth surface transition.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method (300) for manufacturing a composite component (50) includes providing a tool (100) switchable between a deposition configuration (105) and a flange-forming configuration (107). The tool (100) includes a first portion (110) including a first deposition surface (111), a second portion (120) including a second deposition surface (121) and a pre-form support surface (122), and a flange-forming block (130) including a curved surface (131). The method (300) further includes depositing a composite material at least partially on each of the first deposition surface (111) and the second deposition surface (121) in the deposition configuration (105) to provide a composite pre-form (140). The method (300) further includes moving the second portion (120) relative to the first portion (110) to transition the tool (100) to the flange-forming configuration (107), which causes the composite pre-form (140) to at least partially engage each of the pre-form support surface (122) and the curved surface (131). The curved surface (131) defines a radius (51R) of a flange (51) of the composite component (50).