Composite Fan Casing Fiber Texture for Blade-Out Impact Resistance
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Solution Overview
Problem
Existing aircraft engine fan casings made of composite material face challenges in mechanical strength during Fan Blade-Out events, particularly in absorbing impact energy and preventing blade penetration, while maintaining structural integrity and minimizing mass.
Innovation Solution
A fibrous texture with alternating layers of carbon and glass fiber yarns is used, where glass fiber yarns are strategically placed in the impact zone to enhance shear strength and carbon fiber yarns provide axial stiffness, optimizing the casing's mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber yarns are used in the impact zone, then shear strength is enhanced, but axial stiffness is reduced
Solution Approach 1:
The patent applies local quality by using glass fiber yarns specifically in the impact zone (first section) where shear strength is critical for blade-out events, while using carbon fiber yarns in the second section where axial stiffness is more important. This spatial differentiation of material properties resolves the contradiction by providing the right material property in the right location.
Solution Approach 2:
The patent uses a composite fibrous texture combining both glass fiber and carbon fiber yarns in a single structure. The glass fiber provides superior shear strength for impact resistance, while carbon fiber provides axial stiffness, creating a composite material that achieves both properties simultaneously in different zones of the casing.
2Stress or pressure
If carbon fiber yarns are used throughout, then axial stiffness is maintained, but shear strength in impact zone is insufficient
Solution Approach 1:
The patent recognizes that different zones of the casing have different mechanical requirements. The impact zone (first section) requires high shear strength for blade-out events, while other zones require axial stiffness. By locally substituting glass fiber for carbon fiber in the impact zone, the patent optimizes shear strength where it is most needed while maintaining axial stiffness in other areas.
3Ease of manufacture
If uniform material distribution is used, then manufacturing is simplified, but mechanical properties are not optimized for impact zones
Solution Approach 1:
The patent implements local quality through a differentiated fibrous texture with two distinct sections. The first section (impact zone) contains glass fiber yarns for enhanced shear strength, while the second section contains carbon fiber yarns for axial stiffness. This localized material differentiation optimizes impact resistance without significantly complicating the manufacturing process, as the differentiation is achieved through the weaving pattern rather than complex assembly steps.
Data Source
AI summary
A strip-shaped fibrous texture has a three-dimensional or multi-layered weaving between a plurality of layers of warp yarns or strands and a plurality of layers of weft yarns or strands extending in the lateral direction. The fibrous texture includes a first section extending along the longitudinal direction from a proximal portion of the texture and in which one or more layers of the plurality of layers of weft yarns or strands consist of a plurality of groups of yarns or strands each including at least one carbon fiber yarn or strand and one glass fiber yarn or strand. The carbon fiber yarn or strand and the glass fiber yarn or strand of each group of yarns being woven together according to the same weaving pattern or weave. The fibrous texture further includes a second section present between the first section and a distal portion of the fibrous texture.