Composite Lobed Flow Mixer Manufacturing via Intermediate Preform
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Solution Overview
Problem
Manufacturing complex composite material structures, such as gas turbine flow mixers, is challenging due to geometric singularities that make certain areas inaccessible to laying tools, and existing methods struggle to achieve the required shape accuracy and thermal properties like thermal conduction and stiffness.
Innovation Solution
A process involving the production of a fibrous preform with an intermediate geometry that can be post-formed into the final shape using thermoformable or thermosetting resins, with local offsets and heating/pressurization to achieve the desired geometry, and using specific materials like alumina or carbon fibers for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional direct manufacturing methods are used for complex lobed structures, then manufacturing simplicity is maintained, but manufacturing precision and accessibility to geometric singularities deteriorate
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: first producing an intermediate geometric configuration that is accessible to laying tools, then separately performing post-forming to achieve the final complex lobed geometry. This segmentation allows each phase to be optimized independently, resolving the contradiction between manufacturing accessibility and final shape precision.
Solution Approach 2:
The intermediate geometric configuration is produced as a preliminary form that approximates the final lobed structure but with simplified geometry accessible to AFP or sewing tools. This preliminary action enables subsequent post-forming operations to achieve the precise final geometry without requiring direct access to difficult-to-reach areas during initial manufacturing.
2Shape
If complex lobed geometry is manufactured directly, then final shape is achieved, but accessibility to laying tools deteriorates
Solution Approach 1:
The geometry is segmented into an intermediate configuration with large radii of curvature that is accessible to tools, and a final lobed configuration with geometric singularities. The intermediate form serves as a accessible precursor that can be manufactured with standard tools, while the final complex geometry is achieved through subsequent post-forming operations.
Solution Approach 2:
The intermediate geometric configuration acts as an intermediary form between the manufacturable flat or simple curved state and the final complex lobed geometry. This intermediary state allows tools to access and manufacture the base structure, which is then transformed into the final geometry through heating, pressurization, and mechanical deformation processes.
3Strength
If composite material structures are used for flow mixers, then thermal properties and stiffness are improved, but manufacturing complexity increases
Solution Approach 1:
The physical parameters of the composite material are changed by controlling the resin state: starting with a deformable state (thermoformable or pre-pushed thermosetting resin) during intermediate geometry production, then transitioning to a rigid state through curing or setting to maintain the final complex lobed geometry. This parameter change enables the material to be both manufacturable and structurally sound.
Solution Approach 2:
The invention uses composite materials with specific resin characteristics (thermoformable or thermosetting) that enable the two-phase manufacturing process. The composite structure allows the material to be deformable during intermediate form production, then rigidify to maintain the final precision geometry, combining manufacturing flexibility with structural performance.
4Manufacturing precision
If post-forming processes are used to achieve final geometry, then manufacturing precision is improved, but process complexity and time increase
Solution Approach 1:
The intermediate geometric configuration is produced as a preliminary form that is close to the final geometry but with simplified features. This preliminary action reduces the amount of post-forming required, as the bulk of the geometry is already in place, requiring only localized deformation to achieve the final lobed structure, thereby reducing total process time.
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 method allows for the precise and cost-effective production of complex composite structures with improved thermal and mechanical properties, ensuring good thermal conduction, stiffness, and resistance to breakage while maintaining aerodynamic integrity.
Implementation Method 1
exploiting the thermoformable or thermosetting nature of the resin comprises heating the fibrous preform
Implementation Method 2
pressurising said fibrous preform, after it has been brought into contact with a mould with the final geometry
Data Source
AI summary
The invention relates to the production of a composite material of a lobed structure (10) of a flow mixer which comprises a portion having a plurality of lobes (17, 19). For this purpose, a fibrous preform containing a resin will be produced in a simple geometric configuration of developable revolution. This is an intermediate state. By exploiting the thermoformable or thermosetting nature of the resin, the geometry of this intermediate preform is modified to deform it with limited offsets towards the final geometry.