Composite Vane Leading Edge Metal Sheath Bonding
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Solution Overview
Problem
The manufacturing of composite vanes for turbofan engines is hindered by the time-consuming and labor-intensive process of handwork required for leading edge round finish, which increases production time and cost.
Innovation Solution
A composite vane design featuring a metal sheath bonded to the leading edge via a film adhesive, with an underfill section formed during machining to eliminate the need for handwork-based leading edge round finish, reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If handwork is used for leading edge round finish, then the leading edge can be finished into a curved shape, but the manufacturing time and effort increase significantly
Solution Approach 1:
The patent replaces the manual mechanical process of handwork with an automated molding process. The leading edge curved shape is formed during the molding step itself through the mold cavity design, eliminating the need for subsequent manual machining and rounding operations. This substitution of manual mechanical work with automated molding significantly reduces manufacturing time while maintaining the required leading edge geometry.
Solution Approach 2:
The patent performs the leading edge rounding action in advance during the molding process rather than as a post-processing step. The mold cavity is designed to directly form the curved leading edge shape as the composite material is molded, so the rounding action is incorporated into the primary manufacturing operation. This preliminary formation of the final shape eliminates the need for separate handwork operations.
2Reliability
If a metal sheath is bonded to the leading edge section, then wear resistance is improved, but the device complexity increases
Solution Approach 1:
The patent creates a composite structure by bonding a metal sheath to the composite material leading edge section. This combines the wear resistance of metal with the lightweight and structural properties of composite materials. The metal sheath is applied only to the leading edge section where wear resistance is most needed, creating a hybrid structure that optimizes both durability and weight characteristics.
Solution Approach 2:
The patent applies the metal sheath only to the leading edge section rather than the entire vane structure. This localized application provides enhanced wear resistance precisely where the leading edge experiences the most abrasion from air particles and debris, while avoiding the unnecessary weight and complexity that would result from covering the entire vane with metal.
3Manufacturing precision
If the entire leading edge undergoes handwork for round finish, then uniform curved shape is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive manual handwork operations with automated molding processes. The mold cavity is precision-engineered to produce the desired curved leading edge shape directly during molding, eliminating the need for costly manual machining and finishing operations. This substitution maintains geometric uniformity while dramatically reducing labor costs and manufacturing time.
Solution Approach 2:
The patent forms the uniform curved leading edge shape during the initial molding operation rather than requiring subsequent handwork. The mold cavity design incorporates the precise geometry needed, so the uniform curved shape is created in the primary manufacturing step. This preliminary formation eliminates expensive post-processing operations while maintaining the required geometric precision.
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 approach significantly reduces manufacturing time and cost by eliminating the need for handwork on the underfill sections, while maintaining the structural integrity and wear resistance of the composite vane.
Implementation Method 1
a metal sheath that is bonded to a leading edge section including a leading edge of the composite vane body and a vicinity of the leading edge via a film adhesive formed by impregnating a mesh with a hard adhesive
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A composite vane includes a composite vane body 11 that is formed from a composite material of a thermosetting resin or a thermoplastic resin and reinforced fibers, which is obtained by molding, and a metal sheath 12 that is bonded to a leading edge section 11A including a leading edge 11a of the composite vane body 11 and a vane surface 11b in a vicinity of the leading edge 11a via a film adhesive 13 formed by impregnating a mesh with a hard adhesive to cover the leading edge section 11A, wherein an underfill section 11d that is formed in a step of removing excessive thicknesses parts 15 and 16 remaining on the leading edge 11a after the molding and does not need leading edge round finish is placed on the leading edge 11a of the leading edge section 11A in the composite vane body 11. It is possible to realize reduction of manufacturing time and manufacturing cost.