Composite Turbomachine Vane Weaving for Crack-Resistant Attachment Lugs
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Solution Overview
Problem
Existing outlet guide vanes made of composite material face stress concentration at the fillets between lugs and the blade, leading to potential cracks and breaks due to non-optimal mechanical properties in suboptimal directions, compromising structural integrity under various loads.
Innovation Solution
A method for manufacturing a composite material vane with integrated platforms and attaching tabs aligned with the longitudinal axis, eliminating radii between tabs and the vane body, and reinforcing mechanical resistance by diverting warp yarns in non-interlinked areas, ensuring traction and compression alignment with the fiber reinforcement direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If attachment lugs are used to connect the vane to the hub and take-up rods, then the structural function of force transmission is achieved, but stress concentration occurs at the fillets between lugs and blade leading to potential cracks and breaks
Solution Approach 1:
The vane is divided into distinct functional segments: the blade portion and the attachment lug portion. The lug is designed as a separate attachment element that can be integrated or separately attached, allowing independent optimization of each segment for its specific function while reducing stress concentration at transition zones.
Solution Approach 2:
The attachment lug extends perpendicular to the longitudinal axis of the blade, transitioning from a one-dimensional blade structure to a three-dimensional attachment structure. This dimensional change allows force transmission in multiple directions while distributing stresses more evenly across the attachment interface.
2Weight of moving object
If composite material is used to reduce mass while maintaining aerodynamic performance, then weight reduction is achieved, but mechanical properties are reduced in directions perpendicular to fiber orientation
Solution Approach 1:
The composite material structure is optimized with different fiber orientations and densities in different regions. The blade portion uses fiber orientation optimized for aerodynamic loads, while the attachment lug portion incorporates fiber reinforcement specifically oriented to withstand compressive and tensile forces during attachment, creating locally optimized mechanical properties.
Solution Approach 2:
The invention uses composite materials with strategically oriented fiber reinforcements to achieve both weight reduction and directional strength requirements. The multi-directional fiber arrangement in the lug provides enhanced mechanical properties in suboptimal directions while maintaining overall mass reduction benefits of composite materials.
3Ease of operation
If lugs are positioned perpendicular to the longitudinal axis for attachment, then connection to hub and take-up rods is enabled, but compression loads require work in suboptimal directions of the composite material
Solution Approach 1:
The attachment lug is designed with localized fiber reinforcement and optimized material properties specifically at the attachment interface where compression loads are applied. This local quality enhancement ensures adequate compressive strength without compromising the overall lightweight composite structure.
Solution Approach 2:
The lug geometry and fiber orientation are预先 designed to anticipate and prepare for compression loads during attachment. The structure is pre-configured with sufficient mechanical resistance in compression directions, allowing the vane to withstand attachment forces without requiring additional reinforcement or modification.
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 vane achieves enhanced mechanical resistance and structural integrity by distributing stress evenly, reducing the risk of cracks and breaks, particularly at attachment points, while facilitating platform incorporation.
Implementation Method 1
forming, by three-dimensional or multilayer weaving between a plurality of warp yarn layers and a plurality of weft yarn layers, a fiber blank
Implementation Method 2
densifying the preform by a matrix to obtain a fixed turbomachine vane made of composite material
Data Source
AI summary
A method for manufacturing a turbomachine vane made of composite material, the method including forming, by three-dimensional or multilayer weaving, a fiber blank separated across its thickness into first, second and third parts in two non-interlinked areas present at the longitudinal ends of the fiber blank, the first part located between the second and third parts to which it is connected by weaving outside non-interlinked areas, forming, from the fiber blank, a preform of the vane to be produced, by unfolding and shaping, at each longitudinal end and on either side of the first part, the segments of the second part and the segments of the third part not interlinked with the first part to form preform parts for a platform of the vane, the segments of the first part not interlinked with the segments of the second and third parts extending along the longitudinal axis, and densifying the preform.