Turbomachine Fan Blade with 3D Woven Composite Reinforcement
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Solution Overview
Problem
Fan blades in turbomachines face challenges in resisting impacts from objects like birds and hailstones, with current composite material designs compromising on thickness for aerodynamic performance, leading to reduced impact resistance and potential damage.
Innovation Solution
A fan blade design featuring a fibrous reinforcement structure with a three-dimensional weaving pattern, incorporating high Young's modulus first strands and elongation-at-break second strands, along with an intermediate portion for gradual density transition, enhancing impact resistance and aerodynamic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thickness of the composite material structure is reduced to improve aerodynamic performance, then aerodynamic efficiency is improved, but the capacity to resist impact is reduced
Solution Approach 1:
The patent applies local quality by creating distinct zones within the blade structure with different material properties. The leading edge zone contains a specific arrangement of strands with varying orientations and material compositions (including aramid fibers) to provide enhanced impact resistance, while other zones of the blade can be optimized for aerodynamic performance with thinner sections and different strand configurations.
Solution Approach 2:
The patent utilizes composite materials by combining different fiber types (carbon fibers, aramid fibers, glass fibers) with a polymer matrix in a three-dimensional woven structure. This composite approach allows the blade to simultaneously achieve high strength-to-weight ratio for aerodynamic efficiency and localized impact resistance where needed, resolving the contradiction between thinning for aerodynamics and maintaining impact resistance.
2Weight of moving object
If the thickness of the composite material structure is reduced, then weight is reduced, but the capacity to resist impact is reduced
Solution Approach 1:
The patent implements local quality by concentrating enhanced protective structures specifically at the leading edge where impact risks are highest, while allowing other portions of the blade to be thinner and lighter. This localized reinforcement strategy reduces overall blade weight compared to uniform thickening, while still providing necessary impact resistance.
Solution Approach 2:
The patent transitions from traditional two-layer composite structures to a three-dimensional woven fibrous reinforcement structure. This dimensional change allows for more efficient load distribution throughout the blade volume, enabling weight reduction while maintaining or enhancing impact resistance through the three-dimensional architecture and strategic placement of high-strength strands.
3Stress or pressure
If strands with high Young's modulus are used to maintain structural stiffness, then rigidity is improved, but elongation at break is reduced
Solution Approach 1:
The patent employs composite materials by integrating strands with high Young's modulus (such as carbon fibers for stiffness) alongside strands with high elongation at break (such as aramid or glass fibers for ductility). This composite strand architecture allows the blade to simultaneously achieve the required structural stiffness for aerodynamic stability and sufficient elongation capacity to absorb impact energy without catastrophic failure.
Solution Approach 2:
The patent applies local quality by strategically positioning strands with different mechanical properties in specific zones. High Young's modulus strands are placed in regions requiring structural stiffness and load bearing, while high elongation strands are positioned in zones susceptible to impact and requiring energy absorption, optimizing the overall performance balance.
Data Source
Figure 1~2
Figure 2a~2d
Figure 2e~3
AI summary
The invention relates to a blade (3) of a fan (1) of a turbomachine having a structure made of a composite material comprising a fibrous reinforcement (5) obtained by three-dimensional weaving and a matrix in which the fibrous reinforcement (5) is embedded, the fibrous reinforcement (5) comprising first strands (9) having a predetermined elongation at break, a portion of the fibrous reinforcement (5) further comprising second strands (10) having an elongation at break higher than that of the first strands (9).