Movable Counter Mould for Composite Fan Casing Fibre Orientation
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Solution Overview
Problem
Existing methods for manufacturing composite aeronautical parts, such as blower casings, fail to achieve optimal fibre orientation and compaction stresses in areas with radially oriented flanges, leading to suboptimal mechanical strength and fibre content.
Innovation Solution
A manufacturing method using a mould with a cylindrical support and a counter mould comprising movable parts that orient and compact fibres radially and axially, allowing for high fibre content and optimal fibre orientation, with corner elements and metal sheets for smooth gliding and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-piece counter mould is used, then the mould structure is simple, but the fibre orientation and compaction stress are not optimal in radially oriented flange areas
Solution Approach 1:
The counter mould is divided into multiple movable parts instead of being a single piece. This segmentation allows each part to move in specific directions (one towards the axis, another towards the radial wall) to achieve optimal fibre orientation and compaction stress distribution in different areas of the composite part, particularly in the radially oriented flange regions.
2Quantity of substance
If compaction stresses are increased to achieve high fibre content, then fibre content improves, but the mould closure and fibrous reinforcement integrity may be compromised
Solution Approach 1:
Different areas of the mould apply different compaction stresses according to their specific requirements. The movable parts of the counter mould enable localized compaction in flange areas while maintaining appropriate stress levels in other regions, thus achieving high fibre content without compromising the integrity of the fibrous reinforcement or preventing mould closure.
3Ease of manufacture
If the counter mould is moved in a single direction perpendicular to the main surface, then the moulding process is simple, but the fibre orientation in flange areas is not optimal
Solution Approach 1:
The counter mould employs dynamic movement with multiple degrees of freedom rather than a fixed single-direction movement. The movable parts can shift independently in different directions (axial and radial) to optimize fibre orientation during compaction, thereby enhancing mechanical strength while maintaining manufacturing feasibility.
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 ensures the highest fibre content and optimal orientation, achieving improved mechanical strength and efficient resin impregnation, while maintaining the integrity of the fibrous reinforcement and allowing for the final shape to be dried and formed.
Implementation Method 1
the structure being compacted by bringing closer the walls of both parts of the mould
Implementation Method 2
the resin is injected inside the mould after vacuuming the case being
Implementation Method 3
the resin is injected inside the mould after vacuuming the case being
Implementation Method 4
injecting of the polymer matrix in said fibrous structure
Data Source
AI summary
A method for manufacturing an article made of a composite material including a polymer matrix reinforced by a fibrous structure, the method including: placing the fibrous structure on a substrate; forming a molding surface, covering the structure with a mating mold; and compacting the structure by moving the surface of the mating mold toward the surface of the substrate. The substrate includes a cylindrical portion and a wall positioned radially relative to the cylindrical portion, and the mating mold includes two portions that are mobile relative to one another and that are moved toward the axis of the cylindrical portion and towards the radial wall of the substrate, respectively. The method can be used for example for manufacturing a fan casing of a turbojet engine.