Composite Hollow Blade Grid Core Stiffness Optimization
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Solution Overview
Problem
The manufacturing of composite fan blades for turbomachines is cumbersome and results in solid blades that add unnecessary weight and increase operational and manufacturing costs, while existing methods fail to provide sufficient stiffness against unforeseen events like foreign object impacts.
Innovation Solution
A method of forming a composite hollow blade by creating a grid core structure with reinforcing components in a curable matrix material and coupling it with an outer layer, using design parameters to optimize width, spacing, and orientation of reinforcing components, and curing the structure to achieve the desired stiffness and airfoil shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If solid composite fan blades are manufactured using conventional methods, then the blades provide sufficient stiffness to prevent breaking during unforeseen events, but the blades add unnecessary weight to the aircraft and increase manufacturing costs
Solution Approach 1:
The blade is segmented into a hollow structure with internal compartments rather than a solid monolithic form. The hollow blade includes a leading edge portion, trailing edge portion, and spanwise sections that form internal cavities, reducing material usage and weight while maintaining structural integrity through strategic reinforcement at critical locations.
Solution Approach 2:
The patent employs composite materials with fiber reinforcement (such as carbon fiber or glass fiber) embedded in a polymer matrix to create the hollow blade structure. This composite construction provides high strength-to-weight ratio, enabling the hollow design to maintain sufficient stiffness and strength despite reduced material volume compared to solid blades.
2Ease of manufacture
If solid composite fan blades are manufactured, then the blades have sufficient structural integrity, but the manufacturing process is cumbersome and increases operational and manufacturing costs
Solution Approach 1:
A mandrel or core structure is prepared in advance with the desired hollow blade geometry, including internal compartments and reinforcement locations. The composite materials are then applied to this pre-configured mandrel, which automatically forms the hollow structure and internal reinforcement patterns, simplifying the manufacturing process and reducing material waste.
Solution Approach 2:
The manufacturing process utilizes controllable parameters such as fiber orientation angles, layer thickness, and curing conditions to optimize blade performance. By adjusting these parameters during manufacturing, the hollow blade achieves required structural integrity with reduced material consumption compared to solid blade construction.
3Quantity of substance
If the blade structure is made hollow to reduce weight, then material usage and cost are reduced, but the blade may lose sufficient stiffness to handle frequency, foreign object damage, and fan blade out requirements
Solution Approach 1:
The hollow blade features localized reinforcement at critical stress points, such as the root section, leading edge, and trailing edge, while maintaining hollow cavities in less critical regions. This selective reinforcement approach ensures sufficient stiffness and strength for handling frequency loads, foreign object damage, and fan blade out events while minimizing overall material consumption.
Solution Approach 2:
The blade incorporates three-dimensional reinforcement structures, such as circumferential rings, longitudinal stiffeners, and diagonal bracing within the hollow compartments. These multi-dimensional structural elements provide enhanced stiffness and strength in all critical directions, ensuring the hollow blade can withstand complex loading conditions including frequency vibrations, foreign object impacts, and fan blade out forces.
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
The method reduces weight and manufacturing costs by creating a hollow blade with improved stiffness, capable of handling frequency, foreign object damage, and fan blade out requirements, while simplifying the manufacturing process through automation.
Implementation Method 1
a step of curing the core and the outer layer to form the composite hollow blade
Data Source
AI summary
Composite hollow blade and an associated method of forming the composite hollow blade are disclosed. The method includes forming a core by fabricating a grid core structure based on a plurality of design parameters, where the grid core includes a plurality of first reinforcing components disposed in a first curable matrix material. The method further includes forming an outer layer including a plurality of second reinforcing components disposed in a second curable matrix material. Further, the method includes coupling the core to the outer layer and curing the core and the outer layer to form the composite hollow blade.