Composite Turbomachine Compressor Housing Fiber Orientation
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Solution Overview
Problem
Existing composite turbomachine casings face issues with low rigidity and mechanical strength, particularly in external compressor casings subjected to high stresses, and are weakened by thermal and humidity factors, leading to potential contact damage with rotor blades.
Innovation Solution
A composite casing design with a circular wall featuring two outer layers and a central layer, where the fiber reinforcement varies in proportion between axial and circumferential fibers, with helical fibers in intermediate layers, optimizing fiber orientation and distribution to enhance mechanical strength and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a composite housing with a thin wall is used to reduce weight, then the weight of the turbomachine is reduced, but the rigidity and mechanical strength of the housing becomes insufficient
Solution Approach 1:
The patent employs composite materials consisting of a matrix and fibrous reinforcement with a specific multi-layer ply structure. The reinforcement includes a three-dimensionally woven preform and/or a stack of woven fibrous plies with optimized fiber orientations (0°, 90°, ±45°) to simultaneously achieve high mechanical strength and low weight, directly resolving the contradiction between weight reduction and strength maintenance
Solution Approach 2:
The patent implements local quality optimization by modulating the ply orientation and fiber distribution in different regions of the housing wall. The fiber reinforcement is densified by the matrix in specific areas to enhance mechanical strength where needed, while maintaining thinner walls in other regions to reduce overall weight, thus resolving the strength-weight contradiction through spatially varying material properties
2Strength
If the fiber orientation is optimized for strength in certain areas, then the mechanical strength of the housing is improved, but the rigidity remains low and insufficient under high stress
Solution Approach 1:
The patent applies parameter changes by systematically varying the fiber orientation angles (0°, 90°, ±45°) and the proportion of fibers in different directions within the composite structure. This optimization of material parameters enables the housing to simultaneously achieve high mechanical strength and adequate rigidity under thermal, humidity, and mechanical stress conditions
Solution Approach 2:
The use of composite materials with a matrix and fibrous reinforcement creates a structure where the matrix binds the fibers and transfers loads, while the oriented fibers provide both strength and rigidity. This composite architecture resolves the contradiction by enabling the material to exhibit both high strength and sufficient rigidity through the synergistic interaction of matrix and reinforcement phases
3Ease of manufacture
If the housing is made with uniform fiber distribution, then the manufacturing process is simplified, but the mechanical strength under directional stress is reduced
Solution Approach 1:
The patent implements local quality by creating regions with different fiber orientations and densities within the composite housing. The fiber reinforcement is densified by the matrix in specific areas to enhance mechanical strength under directional stress, while maintaining a systematic manufacturing approach through predefined ply stacking sequences and fiber arrangement patterns
4Reliability
If thermal stresses and humidity are present, then the operating conditions are realistic, but the mechanical strength of the casing is reduced
Solution Approach 1:
The patent addresses thermal and humidity effects by optimizing the composite material parameters, including fiber orientation and matrix composition. The fiber reinforcement structure is designed to maintain mechanical strength under thermal stress and humidity exposure, with the matrix providing environmental protection and the oriented fibers maintaining structural integrity under combined thermal-mechanical loading conditions
Data Source
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AI summary
A composite external casing for a compressor of an axial-flow turbomachine, the casing comprising a generally circular wall having a matrix and a woven fibrous reinforcement. The latter is formed by a stack of fibrous plies having fibers woven according to a weft positioned in the axis of the circular wall, and a warp positioned around the circumference of the wall. The stack of plies comprising, depending on thickness, two external layers and one central layer. The layers include differences in the proportions between the weft fibers and the warp fibers. In the external layers the warp fibers make up the majority. In the central layer the weft fibers make up the majority. The stack exhibits interlayers inserted between the central layer and each external layer. The plies corresponding to the interlayers exhibit fibers woven at +45° and −45° in relation to the axis of rotation of the turbomachine.