Hollow Composite Turbomachine Vane Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing outlet guide vanes (OGVs) in turbomachines face challenges in achieving a suitable mechanical strength-to-mass ratio, particularly for large diameters, as composite materials do not adequately reduce mass compared to hollow metal OGVs, impacting aerodynamic performance and increasing manufacturing costs.
Innovation Solution
A method involving three-dimensional weaving of threads, cutting to create internal separations, deformation to form open ends, injection molding with a resin binder, and using a flexible mandrel to create a hollow core, which is then polymerized and sealed, optimizing mechanical properties and mass reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite materials are used to manufacture outlet guide vanes, then manufacturing cost is reduced, but mechanical strength-to-mass ratio is insufficient for large diameter turbomachines
Solution Approach 1:
The patent uses composite materials consisting of a hollow core (metal or foam) combined with composite fabric plies draped over it. This composite structure achieves both cost reduction through composite material usage and adequate mechanical strength-to-mass ratio by strategically combining different materials with complementary properties.
Solution Approach 2:
The patent employs a nested structure where composite fabric plies are draped over a hollow core, creating a layered composite structure. The hollow core provides structural framework while the composite plies provide surface strength and aerodynamic properties, achieving optimal strength-to-mass ratio.
2Weight of stationary object
If hollow metal OGVs are used, then mass is reduced compared to solid metal, but mass is still too high for large diameter turbomachines
Solution Approach 1:
The patent replaces solid metal construction with composite materials that have superior strength-to-mass ratios. The composite structure combines hollow core with draped fabric plies, achieving both mass reduction and adequate mechanical strength for large diameter applications.
Solution Approach 2:
The patent applies different material properties to different regions of the vane structure. The hollow core provides structural support where needed, while the composite fabric plies provide surface strength and aerodynamic properties, optimizing the strength-to-mass ratio locally throughout the structure.
3Strength
If composite OGVs are made by successive draping around a central core, then mechanical strength is achieved, but mass is similar to hollow metal OGVs for large diameters
Solution Approach 1:
The patent uses composite materials with optimized structure to achieve superior strength-to-mass ratio. By combining hollow core with strategically draped composite fabric plies, the structure achieves both adequate mechanical strength and reduced mass compared to traditional approaches.
Solution Approach 2:
The patent divides the vane structure into distinct segments: hollow core providing structural framework and composite fabric plies providing surface properties. This segmentation allows each component to be optimized independently for its specific function, achieving optimal overall strength-to-mass ratio.
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 produces composite parts with enhanced mechanical strength-to-mass ratio, allowing for lighter and more efficient structural components with improved aerodynamic performance and reduced manufacturing costs.
Implementation Method 1
f) the resin is polymerised
Data Source
AI summary
The invention relates to a method for manufacturing a hollow part made of composite material for an aircraft turbomachine, wherein: a) a preform is produced by the three-dimensional weaving of threads; b) the preform is cut so as to provide a separation; c) the cut preform is deformed so as to provide an orifice then comprising a first and a second open end (27a, 27b); d) the deformed preform is placed into an injection mould; e) a resin is injected in order to impregnate the whole of the deformed preform; f) the resin is polymerised; and g) a composite part is extracted from the mould; characterised in that: h) a flexible mandrel (31) with a predetermined shape is positioned in the orifice before the injection step e); i) the flexible mandrel (31) is removed after step f) or the demoulding step g), the composite part then having a hollow core (25).