Nested Mold Shaping Fibrous Preform for Turbine Blades
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Solution Overview
Problem
Current mold technologies used in the RTM process for manufacturing turbomachine bladed parts are complex and expensive due to their dual function of shaping the preform and injecting resin, and they are not suitable for positioning and fixing a metal shield on the leading edge of the bladed part.
Innovation Solution
A device comprising a mold with nested parts, specifically designed and optimized for shaping the fiber preform by compressing and heating, and capable of precisely positioning and fixing a metal shield on the leading edge of the preform, allowing for partial disassembly for easy access and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single mold is used for both shaping and resin injection, then the number of molds is reduced, but the mold complexity and cost increase
Solution Approach 1:
The mold is divided into multiple independent parts: a fixed part and a movable part that can detach. This segmentation allows each part to be optimized for specific functions while maintaining overall versatility. The movable part can be removed to access the preform for shield positioning, while the fixed part maintains structural integrity.
Solution Approach 2:
The mold incorporates a movable part that can be detached from the fixed part, transforming the mold from a static to a dynamic system. This dynamic capability enables the mold to adapt between different operational phases: closed position for shaping/resin injection and open position for shield positioning and preform removal.
2Ease of manufacture
If a single mold is used for both shaping and resin injection, then equipment investment is reduced, but the ease of operation for shield positioning deteriorates
Solution Approach 1:
By segmenting the mold into detachable parts, the system enables easy access to the preform for shield positioning operations. The movable part can be completely removed, providing unobstructed access to the preform's leading edge where the shield needs to be positioned, while still maintaining cost-effectiveness through single-mold usage.
Solution Approach 2:
The dynamic detaching capability of the movable mold part transforms the operational workflow, allowing seamless transition between closed-mold operations (shaping, resin injection) and open-mold operations (shield positioning, preform removal), thereby improving ease of operation without requiring multiple molds.
3Ease of operation
If the mold is designed with multiple detachable shell elements, then the ease of operation for shield positioning is improved, but the device complexity increases
Solution Approach 1:
The mold is segmented into a fixed part and a movable part, with the movable part further divided into multiple shell elements (first, second, third shells). This hierarchical segmentation provides progressive access: the movable part detaches for general access, and individual shell elements can be removed for specific access points, balancing operational ease with structural manageability.
Solution Approach 2:
The mold structure employs a nested arrangement where shell elements are organized in layers (first, second, third shells) that can be sequentially accessed. This nesting provides organized access to different regions of the preform while maintaining a manageable structural hierarchy that doesn't excessively increase device complexity.
4Manufacturing precision
If the mold uses a multi-element shell structure, then the manufacturing precision for shield positioning is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The multi-element shell structure is designed with standardized interfaces and systematic organization. Each shell element serves a specific function and can be manufactured independently with controlled tolerances, allowing precise positioning capabilities while maintaining manufacturability through modular assembly rather than monolithic construction.
Solution Approach 2:
Different shell elements are designed with specific local qualities optimized for their functions: certain shells provide structural support, others provide access pathways, and specific elements incorporate features for shield positioning. This localized optimization achieves high positioning precision without requiring excessive complexity across the entire mold structure.
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 device enables efficient shaping of the preform and precise attachment of the metal shield, reducing the complexity and cost of the mold while enhancing the manufacturing process's flexibility and precision.
Implementation Method 1
a heating element arranged to heat the resin to a temperature sufficient to polymerize the resin
Implementation Method 2
the resin is injected through a feed port in the mold, which is then placed in an oven to cause the resin to polymerize and harden
Data Source
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AI summary
The invention relates to a device (30) for shaping at least one fibrous preform of a bladed part (10) of a turbine engine, the device comprising a mould (34) formed of multiple parts nested inside one another, the mould defining an internal cavity (32) for enclosing said preform entirely, said cavity (32) having two platform zones (Z2, Z3) and a blade zone (ZZ1) extending between the two platform zones, characterised in that said mould (34) comprises at least a lower shell (38), an upper shell (46), a side shell (40), and end shells (42, 44), and in that each of the side (40) and end (42, 44) shells comprises three elements, respectively lower (40a, 42a, 44a), intermediate (40b, 42b, 44b) and upper (40c, 42c, 44c).