3D-Woven Inter-Blade Platform With Preformed Sacrificial Edges
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Solution Overview
Problem
The manufacturing of inter-blade platforms in turbomachine fans is complex due to the need for precise machining of sacrificial edges in composite materials, leading to material waste and dimensional inaccuracies.
Innovation Solution
A method involving three-dimensional weaving and membrane injection molding is used to create a fibrous preform with a shape similar to the final part, eliminating the need for complex machining and ensuring precise fiber content and dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sacrificial lateral edges are machined from composite material base edges, then the desired thickness reduction is achieved, but the manufacturing process becomes complex and delicate with difficulty in maintaining dimensional accuracy and surface joints
Solution Approach 1:
The fiber preform is prepared in advance with the sacrificial lateral edges already integrated into its structure before densification. This preliminary shaping of the preform eliminates the need for subsequent machining operations, thereby simplifying the manufacturing process while maintaining dimensional accuracy and surface quality of the composite platform
Solution Approach 2:
The complex machining operation is extracted and eliminated from the manufacturing process. Instead of machining the sacrificial edges from the base after composite fabrication, the preform is designed to include these edges as integral parts, removing the problematic machining step entirely
2Shape
If sacrificial lateral edges are machined from composite material, then thickness reduction is achieved, but material waste increases
Solution Approach 1:
The sacrificial lateral edges are pre-formed as integral parts of the fiber preform structure before densification. This preliminary configuration ensures that the exact required thickness and geometry are achieved during the molding process itself, eliminating material removal and associated waste
Solution Approach 2:
The manufacturing approach changes from subtractive machining to additive/formative molding. By controlling the fiber preform parameters and densification process, the desired thickness reduction is achieved through material placement rather than material removal, thereby preventing waste
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 simplifies manufacturing, reduces material waste, and ensures adherence to dimensional specifications while improving mechanical properties of the inter-blade platforms.
Implementation Method 1
an impregnation fluid being injected into the impregnation chamber
Implementation Method 2
a compression fluid being injected into the compaction chamber so as to apply pressure on the membrane
Implementation Method 3
an impregnation chamber closed by a flexible membrane separating said impregnation chamber from a compaction chamber
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a method for manufacturing an inter-blade platform (100) of a turbomachine fan (1), the platform (100) comprising a base (110) having first and second sacrificial lateral edges (131, 132) having a thickness which is less than that of the central part (120) of the base (110), the method comprising producing a preform (200) of the platform (100) by three-dimensional weaving, comprising a central part portion (220) and two sacrificial edge portions (231, 232) whose thickness is less than that of the central part portion (220), the difference in thickness between the lateral edge portions (231, 232) and the central part portion (220) being produced by removing a plurality of warp threads situated outside the central part portion (220) and not being woven with weft threads.