3D Woven Composite Preform With Integrated Service Tube Cavity
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Solution Overview
Problem
Manufacturing composite components for turbine engines, particularly those with integrated service tubes, is challenging due to machining difficulties and increased thickness requirements, which affect producibility and efficiency.
Innovation Solution
A method involving three-dimensional woven fabrics is employed, where the service tube is co-molded with the composite material, eliminating the need for additional machining and reducing thickness by integrating the tube during the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If service tubes are integrated into composite components using traditional methods, then the component functionality is improved, but the manufacturing complexity and thickness increase
Solution Approach 1:
The patent combines the service tube and composite component into a single integrated structure by co-molding them together. The fiber reinforcement extends continuously from the composite component into the service tube, creating a unified part that eliminates separate machining operations and reduces manufacturing complexity while maintaining full functionality of both the component and service tube
2Adaptability or versatility
If service tubes are integrated into composite components using traditional methods, then the component functionality is improved, but the component thickness increases
Solution Approach 1:
The service tube and composite component are co-molded as a single integrated part, eliminating the need for separate tube installation and machining operations that would increase thickness. The fiber reinforcement provides structural continuity while allowing the service tube to be formed directly as part of the molding process, reducing overall component thickness
3Adaptability or versatility
If additional processing steps are used to integrate service tubes, then the component functionality is improved, but the manufacturing efficiency decreases
Solution Approach 1:
The service tube and composite component are manufactured in a single co-molding operation, eliminating multiple separate processing steps such as machining cavities, installing tubes, and performing additional machining. The fiber reinforcement is laid up to form both the component and service tube structure simultaneously, then both are cured together in one autoclave cycle, significantly improving manufacturing efficiency while maintaining full functionality
Data Source
AI summary
A method of manufacturing a woven fabric for a composite component for a turbine engine. The method includes weaving a plurality of reinforcing fiber tows to form a woven fabric with a surface. The reinforcing fiber tows include a plurality of first fiber tows and a plurality of second fiber tows oriented transversely to the plurality of first fiber tows. The woven fabric is a three-dimensional woven fabric. The method also includes forming, during weaving the plurality of reinforcing fiber tows, a cavity extending in the first direction. Forming the cavity includes positioning the plurality of first fiber tows to create the cavity and weaving the plurality of second fiber tows around the cavity. The method further includes forming, during weaving the plurality of reinforcing fiber tows, a slit connecting the cavity to the surface.