3D Woven Composite Preform with Variable Thickness
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Solution Overview
Problem
Existing methods for manufacturing composite material parts, such as turbine engine blades, face challenges with complex and costly production processes due to the use of inserts and high fiber fractions, which lead to material losses, mechanical issues, and difficulties in achieving uniform mechanical properties, especially in regions with varying thickness like the blade root.
Innovation Solution
A 3D or multilayer fiber structure with braids in the core and varying yarn weights is used to achieve controlled thickness variations and fiber fractions, ensuring good matrix infiltration and preventing delamination, without the need for additional inserts, by interlinking weft and warp layers through three-dimensional weaving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If inserts are used to form bulb-shaped regions in composite material parts, then thickness variation is achieved, but manufacturing complexity increases and production cost increases
Solution Approach 1:
The fiber structure is divided into multiple portions with different thicknesses (first portion with greater thickness, second portion with smaller thickness), allowing the bulb-shaped region to be formed directly in the fiber structure without requiring separate inserts. This segmentation enables thickness variation while simplifying the overall manufacturing process.
Solution Approach 2:
The insert is completely removed from the design. Instead of using an insert to create the bulb-shaped region, the invention directly forms the thickness variation through the fiber structure itself, extracting the unnecessary intermediate component and simplifying the manufacturing process.
2Shape
If inserts are used to form bulb-shaped regions, then thickness variation is achieved, but material losses increase
Solution Approach 1:
The bulb-shaped region is merged directly into the fiber structure as an integrated portion rather than being a separate insert. This merging eliminates the need for additional material to create the bulb-shaped region and reduces material losses associated with insert removal and rework.
3Shape
If yarns of high weight are used in portions of greater thickness, then thickness is increased, but fiber fraction increases excessively
Solution Approach 1:
Different portions of the fiber structure use different yarn weights locally. The first portion uses yarns of first weight while the second portion uses yarns of second weight, allowing thickness variation without excessive fiber fraction increase. This local differentiation optimizes both thickness control and matrix infiltration.
4Shape
If high fiber fraction is used in preform, then thickness is increased, but matrix infiltration is hindered
Solution Approach 1:
The fiber fraction parameter is controlled by selecting appropriate yarn weights for different portions. By using yarns of first weight in the first portion and yarns of second weight in the second portion, the invention achieves thickness variation while maintaining fiber fraction within optimal ranges for matrix infiltration.
Data Source
AI summary
A fiber structure includes a plurality of weft layers and a plurality of warp layers interlinked with three-dimensional or multilayer weaving, the fiber structure including at least first and second portions that are adjacent in the warp direction, the first portion presenting thickness in a direction perpendicular to the warp and weft directions that is greater than the thickness of the second portion. The weft layers situated in the core of the first portion of the fiber structure include braids. The weft layers extending on either side of the weft layers including the braids and going as far as the skin of the first portion include yarns or strands, the braids presenting a section greater than the section of the yarns or strands.