CN110439630B - Variable-thickness composite stator blade and forming method thereof - Google Patents
Variable-thickness composite stator blade and forming method thereof Download PDFInfo
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- CN110439630B CN110439630B CN201910741549.9A CN201910741549A CN110439630B CN 110439630 B CN110439630 B CN 110439630B CN 201910741549 A CN201910741549 A CN 201910741549A CN 110439630 B CN110439630 B CN 110439630B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/005—Selecting particular materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D9/00—Stators
- F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
- F01D9/04—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector
- F01D9/041—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles forming ring or sector using blades
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
Abstract
The invention relates to a variable-thickness composite stator blade and a forming method thereof, in particular to an integral forming technology of the variable-thickness stator blade, and belongs to the technical field of advanced composite materials. The blade comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by a wear-resistant nonmetal edge covering. The forming die is designed into a combined die of a closed die cavity 4-piece combined die block, and a conical guide limiting matching surface is designed between the die blocks. And combining the extracted neutral surface and net volume filling method of the blade body, and simulating and designing a sideline outline of each laid prepreg block layer, which is consistent with the total thickness of different areas of the blade body. The blade is manufactured by adopting continuous fiber fabric prepreg on a 4-segment forming die, then the metal embedded sleeve is embedded at a corresponding position, and the co-curing preparation of the embedded part and the blade body is realized by utilizing a hot pressing process. The forming method ensures that the stator blade can meet the requirements of structural strength and rigidity and the profile precision of the aerodynamic shape of the stator blade.
Description
Technical Field
The invention relates to a variable-thickness composite stator blade and a forming method thereof, in particular to an integral forming technology of the variable-thickness stator blade, and belongs to the technical field of advanced composite materials.
Background
The resin-based composite material has good properties such as specific strength, specific modulus and the like, so that the resin-based composite material becomes a popular material for researching cold-end parts of aeroengines. Through decades of development, the resin-based composite material has important application in an outer culvert casing, a rotor and a stator blade, a contained casing, an engine nacelle and a thrust reverser of a large-bypass-ratio turbofan engine and a small-bypass-ratio thrust turbine fan engine.
Stator components of aircraft engines are also increasingly using fibre reinforced resin based composites. For example, PW4056/4168/4084 engine fan outlet guide vanes from P & W company use compression molded carbon fiber reinforced epoxy resin based composites; the compressor stator blade of the PW4084 and PW4168 engines adopts PR500 epoxy resin-based composite material of 3M company, and compared with the stator blade made of titanium alloy material, the stator blade made of the material has the advantages that the weight is reduced by 39 percent, and the cost is reduced by 38 percent. The PW8000 engine of German MTU company adopts PMC composite material in the inlet guide vane and the 1 st and 2 nd adjustable stator vanes of high-speed low-pressure compressor. However, the construction of China in the field of resin-based composite stator blades is still under exploration, and is relatively immature in countries such as Europe and America. The composite material stator blade and the forming technology thereof in China are developed later, and the research on the carbon fiber composite material stator blade is less.
At present, the stator blade in China is made of metal, glass fiber reinforced plastic or low-performance carbon fiber composite materials, but the requirement for higher requirements of the stator blade of an aero-engine cannot be met in comprehensive performance, and the stator blade with light weight, high rigidity, high strength and high profile precision is urgently needed to be developed. Although the composite material is applied to the stator vane, the report can not meet the higher performance requirements (performance requirements of large thickness change, high rigidity, high strength and the like).
Disclosure of Invention
The technical problem solved by the invention is as follows: the manufacturing method solves the manufacturing problem of the variable-thickness stator blade for the high-performance aero-engine, provides the variable-thickness composite stator blade and the forming method thereof, and achieves good control of internal quality and pneumatic outer molded surface through combined die design, net-thickness prepreg sideline outline and hot pressing process design, so as to complete forming of the high-performance variable-thickness composite stator blade.
The technical scheme of the invention is as follows: the stator blade comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the variable-thickness blade body is positioned between the front edge plate and the rear edge plate, the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by an abrasion-resistant non-metal edge covering.
In an alternative embodiment, the front edge plate, the blade body and the rear edge plate are all made of carbon fiber fabric reinforced and toughened epoxy resin composite materials.
In an alternative embodiment, the carbon fiber comprises grade T700, T800, T100, M40J carbon fiber, the carbon fiber fabric form comprises plain weave, twill, five satin or eight flyaway, and the resin content of the composite material is between 38% and 48%.
In an optional embodiment, the local thickening of the assembly connection area of the leading edge plate is enhanced, a metal embedded sleeve is arranged in the connection area, and the metal embedded sleeve and the leading edge plate are integrally formed.
In an optional embodiment, the pre-buried sleeve is made of aluminum alloy or titanium alloy.
In an optional embodiment, the non-metal edge covering material is polyurethane or polyimide.
The invention discloses a forming method of a variable-thickness composite stator blade, which is characterized by comprising the following steps of:
1) the outer shape surface of the blade body of the stator blade is a net-size non-processing surface, the forming die is designed to be a combined die of a closed die cavity 4-piece combined die, front and rear edge plate paving areas are reserved on two sides of the upper and lower end face dies of the blade body, 4 corners are designed to be conical guide limiting, and the upper and lower end face dies are ensured not to deviate after being matched; meanwhile, the front and rear edge plate side molds are designed to be conical matching surfaces, and a compaction in-place step is reserved to ensure that the front and rear edge plate side molds are pressed and attached to the designed position;
2) According to the structural characteristics of the blade and the requirements of a pneumatic profile, a net volume filling method is adopted, and according to the extracted neutral surface of the blade body, a three-dimensional solid surface and a sideline outline of each laid prepreg layer, which are consistent with the total thickness of different areas of the blade body, are designed in a simulated mode;
3) converting the edge line profile of each layer of material blocks obtained in the step 2) into a two-dimensional graph, and arranging the two-dimensional graph according to the edge lines of the graph from large to small; then, combining the characteristics of the edge plate and the layering symmetry principle, designing and cutting a continuous fiber prepreg block of the integral blade;
4) laying the prepreg block cut in the step 3) on the working faces of the upper and lower end face dies of the blade body by taking parting lines on two sides of the blade body as positioning reference lines, and closing the dies after finishing laying and pasting the prefabricated body to obtain the prefabricated body of the blade body;
5) taking the blade body prefabricated body obtained in the step 4) out of the die, attaching the edge-covering cut according to the size to the windward side of the prefabricated blade body, and then putting the prefabricated blade body into the upper and lower end dies of the blade body to close the die and compact the die;
6) paving at least two layers of prepreg blocks on the front edge plate side mold according to the paving sequence, then laminating the corresponding prepreg blocks according to the thickness and size requirements of a connecting area, sucking glue and compacting, paving the prepreg blocks on the front edge plate side mold, and finishing paving and pasting the residual prepreg blocks; embedding the metal embedded sleeve in the paved connecting area; paving and pasting prepreg blocks on the rear edge plate side mold according to the paving sequence;
7) Attaching the front edge plate obtained in the step 6) to the position of the front edge plate after die assembly in the step 5), positioning and compacting; then attaching the rear edge plate side mold subjected to layering to the position of the rear edge plate subjected to mold closing in the step 5) to complete layering of the integral blade;
8) coating auxiliary materials on the outer side of the combined die in the step 7), and realizing co-curing preparation of the integral blade by adopting a hot pressing process;
9) and processing the allowance rim charge of the front edge plate and the rear edge plate of the solidified stator blade so as to meet the size design requirement of the blade.
In an optional embodiment, the glue absorption in the step 6) is carried out in an autoclave or a hot press, the glue absorption temperature is 60-80 ℃, the glue absorption time is 20-40 min, and the pressure in the autoclave is 0.3-0.6 MPa; and vacuumizing the prepreg block to be subjected to glue suction in the glue suction process.
In an optional embodiment, the curing process in the step 8) is performed in an autoclave or a hot press, the curing temperature is 120-130 ℃ or 165-180 ℃, the curing time is 3-6 h, and the pressure in the autoclave is 0.6-1.0 MPa.
The stator blade made of the variable-thickness composite material by the forming method is suitable for an aeroengine.
Compared with the prior art, the invention has the beneficial effects that:
the invention provides a novel variable-thickness composite stator blade and a forming method. The stator blade comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by a wear-resistant nonmetal wrapping edge. The molding die is designed as a combined die of a closed die cavity 4-piece combined die block. And (3) adopting a net volume filling method to simulate and design to obtain the sideline profile of the separation material sheet meeting the total thickness of the blade body. The stator blade is manufactured by hot pressing process integral co-curing, and the pneumatic profile of the blade body is not subjected to secondary machining; the process ensures that the stator blade can meet the requirements of structural strength and rigidity and the surface shape precision of the aerodynamic shape of the stator blade.
The invention has obvious technical advantages, and can be popularized and applied to high-performance stator vanes of military/civil aircraft engines and light-weight bearing structures with higher requirements on aerodynamic appearance, rigidity and strength. The invention can meet the development requirement of increasingly high-performance stator blades of aeroengines in China, and has outstanding economic benefit and prospect.
Drawings
FIG. 1 is an overall structure view of a stator blade;
FIGS. 2a, 2b, 2c and 2d are respectively an integral view of a stator blade forming mold assembly, a lower blade body mold view, an upper blade body mold view and a front edge side plate mold view;
FIG. 3a is a stator vane neutral plane left web lamination view;
FIG. 3b is a web lamination view from the right side of the neutral plane of the stator vane.
Detailed Description
The stator blade comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the variable-thickness blade body is positioned between the front edge plate and the rear edge plate, the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, the windward side of the blade body is protected by an abrasion-resistant non-metal edge covering, and the structural schematic diagram of the blade is shown in an attached figure 1.
Specifically, in the embodiment of the invention, the front edge plate, the blade body and the rear edge plate are all made of carbon fiber fabric reinforced toughened epoxy resin composite materials. The carbon fiber comprises T700, T800, T100 and M40J-grade carbon fibers, the carbon fiber fabric comprises plain weave, twill, five satin or eight sandfly, and the resin mass content of the composite material is 38-48%. The local thickening in leading edge plate erection joint region is strengthened, sets up the pre-buried cover of metal in this joining region, and the pre-buried cover of metal and leading edge plate integrated into one piece. The pre-buried sleeve is made of aluminum alloy or titanium alloy. The non-metal edge covering material is polyurethane or polyimide.
The invention discloses a variable-thickness composite stator blade forming method which is characterized by comprising the following steps of:
1) the outer shape surface of the blade body of the stator blade is a net-size non-processing surface, the forming die is designed to be a combined die of a closed die cavity 4-piece combined die, front and rear edge plate paving areas are reserved on two sides of the upper and lower end face dies of the blade body, 4 corners are designed to be conical guide limiting, and the upper and lower end face dies are ensured not to deviate after being matched; meanwhile, the front and rear edge plate side molds are designed to be conical matching surfaces, and a compaction in-place step is reserved to ensure that the front and rear edge plate side molds are pressed and attached to the designed position; the die design is shown in figures 2a-2 d.
Specifically, in the embodiment of the invention, the material of the die is preferably Q235 steel, 45# steel or P20 steel.
2) According to the structural characteristics of the blade and the requirements of a pneumatic profile, a net volume filling method is adopted, and according to the extracted neutral surface of the blade body, a three-dimensional solid surface and a sideline outline of each laid prepreg layer, which are consistent with the total thickness of different areas of the blade body, are designed in a simulated mode; obtaining two groups of material block boundaries according to the volumes of two sides of a neutral surface of the leaf body;
specifically, in the embodiment of the present invention, each prepreg block with different thickness in different areas of the blade body is designed according to the thickness of each position of the target blade and the single-layer thickness of the prepreg used, so as to obtain prepregs with different sizes and positions for all the paving, as shown in fig. 3a and 3 b.
3) Converting the side line profile of each layer of material blocks obtained in the step 2) into a two-dimensional graph, and arranging the two-dimensional graph according to the size of the side line of the graph; then, combining the characteristics of the edge plate and the layering symmetry principle, designing and cutting a continuous fiber prepreg block of the integral blade;
specifically, in the embodiment of the invention, according to the two-dimensional graph, the layering sequence of each material block layer in the volume on two sides of the neutral plane of the blade body is obtained.
4) Laying the prepreg block cut in the step 3) on the working faces of the upper and lower end face dies of the blade body by taking parting lines on two sides of the blade body as positioning reference lines, and closing the dies after finishing laying and pasting the prefabricated body to obtain the prefabricated body of the blade body;
specifically, in the embodiment of the invention, during the process of laying the prepreg blocks, each 3-5 layers of the prepreg blocks are vacuumized and compacted.
5) Taking out the blade body prefabricated body obtained in the step 4) from the die, attaching the edge-covering cut according to the size to the windward side of the prefabricated blade body, and then putting the prefabricated blade body into the upper and lower end dies of the blade body to close the die and compact the die.
6) Paving at least two layers of prepreg blocks on the front edge plate side mold according to the paving sequence, then laminating the corresponding prepreg blocks according to the thickness and size requirements of a connecting area, sucking glue and compacting, paving the prepreg blocks on the front edge plate side mold, and finishing paving and pasting the residual prepreg blocks; embedding the metal embedded sleeve in the paved connecting area; paving and pasting prepreg blocks on the rear edge plate side mold according to the paving sequence;
Specifically, in the embodiment of the invention, the glue absorption is carried out in an autoclave or a hot press, the glue absorption temperature is 60-80 ℃, the glue absorption time is 20-40 min, and the pressure in the autoclave is 0.3-0.6 MPa; and vacuumizing the prepreg block to be subjected to glue suction in the glue suction process.
7) Attaching the front edge plate obtained in the step 6) to the position of the front edge plate after die assembly in the step 5), positioning and compacting; and then attaching the rear edge plate side mold subjected to layering to the position of the rear edge plate subjected to mold closing in the step 5) to complete layering of the integral blade.
8) Coating auxiliary materials on the outer side of the combined die in the step 7), and realizing co-curing preparation of the integral blade by adopting a hot pressing process;
specifically, in the embodiment of the invention, the curing process is carried out in an autoclave or a hot press, the curing temperature is 120-130 ℃ or 165-180 ℃, the curing time is 3-6 h, and the pressure in the autoclave is 0.6-1.0 Mpa.
9) Processing the allowance rim charge of the front edge plate and the rear edge plate of the solidified stator blade so as to meet the size design requirement of the blade;
in an optional embodiment, the curing process in the step 8) is performed in an autoclave or a hot press, the curing temperature is 120-130 ℃ or 165-180 ℃, the curing time is 3-6 h, and the pressure in the autoclave is 0.6-1.0 MPa.
The following are several specific embodiments of the invention:
example 1
The stator blade made of the variable-thickness composite material comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the variable-thickness blade body is positioned between the front edge plate and the rear edge plate, the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by an abrasion-resistant non-metal edge covering. The reinforcement used by the manufacturing materials of the front edge plate, the blade body and the rear edge plate is T800 carbon fiber twill fabric, the resin matrix is toughened 603-ring epoxy resin, the prepared prepreg is T800-6k-XW/603, and the thickness of a single layer after curing is 0.2 mm.
The thickness of the blade body is gradually changed from 5.5mm to 1.0mm from the root part of the front edge plate to the root part of the rear edge plate; the maximum 0.8mm of the left edge of the blade body is increased to 5.0mm, and then gradually changed to 0.9 mm. The thickness of the front edge plate and the rear edge plate is 3 mm. The local thickening and strengthening of the assembling and connecting area of the front edge plate are realized, and the thickness of the thickening area is 20 mm; a metal embedded sleeve is arranged in the connecting area, and the metal embedded sleeve and the front edge plate are integrally formed. The wear-resistant wrapping edge is made of polyurethane, and the metal embedded sleeve is made of titanium alloy.
The forming method of the stator blade made of the variable-thickness composite material comprises the following steps:
1) The outer shape surface of the blade body of the stator blade is a net-size non-processing surface, the forming die is designed to be a combined die of a closed die cavity 4-piece combined die, front and rear edge plate paving areas are reserved on two sides of the upper and lower end face dies of the blade body, 4 corners are designed to be conical guide limiting, and the upper and lower end face dies are ensured not to deviate after being matched; meanwhile, the front and rear edge plate side molds are designed to be conical matching surfaces, and a compaction in-place step is reserved to ensure that the front and rear edge plate side molds are pressed and attached to the designed position; the material of the die is preferably 45# steel;
2) according to the structural characteristics of the blade and the requirements of the pneumatic profile, a net volume filling method is adopted, according to the extracted neutral surface of the blade body, the thickness of each position of the target blade and the thickness of a single layer of the prepreg are adopted, and the three-dimensional solid surface and the side line profile of each laid prepreg block layer, which are consistent with the total thickness of different areas of the blade body, are designed in a simulated mode; two groups of 29 layers of material block boundaries are obtained according to the volumes of two sides of the neutral plane of the blade body;
3) converting the edge line profile of each layer of material blocks into a two-dimensional graph, and arranging the two-dimensional graph from large to small according to the edge line of the graph; then combining the characteristics of the edge plate and a quasi-isotropic layering sequence design principle to obtain a layering sequence design of each material block layer in the volumes of two sides of the neutral surface of the blade body and cutting a continuous fiber prepreg block of the integral blade;
4) Laying the cut prepreg blocks on working surfaces of dies on the upper end surface and the lower end surface of the leaf body according to the positioning reference line by taking parting lines on the two sides of the leaf body as the positioning reference line, vacuumizing and compacting each 3-5 layers of the prepreg blocks, and closing the dies after paving and pasting the prefabricated body to obtain the prefabricated body of the leaf body;
5) taking the obtained prefabricated body of the blade body out of the die, attaching the edge-covering cut according to the size to the windward side of the prefabricated blade body, and then putting the prefabricated body of the blade body into the upper die and the lower die for die assembly and compaction;
6) paving two layers of prepreg blocks on a front edge plate side mold according to the paving sequence, then laminating the corresponding prepreg blocks according to the thickness and size requirements of a connection area, and carrying out glue suction in a hot pressing tank or a hot pressing machine, wherein the glue suction temperature is 70 ℃, the glue suction time is 30min, and the pressure in the hot pressing tank is 0.6 Mpa; after the glue is absorbed and compacted, paving and pasting the prepreg on the front edge plate side mold, and finishing paving and pasting of the residual prepreg blocks; embedding the metal embedded sleeve in the paved connecting area; paving and pasting prepreg blocks on the rear edge plate side mold according to the paving sequence;
7) attaching the front edge plate obtained in the step 6) to the position of the front edge plate after die assembly in the step 5), positioning and compacting; and then attaching the rear edge plate side mold subjected to layering to the position of the rear edge plate subjected to mold closing in the step 5) to complete layering of the integral blade.
8) Coating the auxiliary material on the product to be cured obtained in the step 7), and curing in an autoclave or autoclave at 180 ℃ for 4h under the curing pressure of 0.7 Mpa; and co-curing preparation of the embedded part and the blade body is realized by adopting a hot pressing process, so that the prepared composite material stator blade is obtained.
9) And processing the allowance rim charge of the front edge plate and the rear edge plate of the solidified stator blade so as to meet the size design requirement of the blade.
Example 2
The stator blade made of the variable-thickness composite material comprises a front edge plate, a variable-thickness blade body and a rear edge plate, wherein the variable-thickness blade body is positioned between the front edge plate and the rear edge plate, the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by an abrasion-resistant non-metal edge covering. The reinforcement used by the manufacturing materials of the front edge plate, the blade body and the rear edge plate is T800 carbon fiber twill fabric, the resin matrix is toughened 602-ring epoxy resin, the prepared prepreg is T800-6k-XW/602, and the thickness of a single layer after curing is 0.2 mm.
The thickness of the blade body is gradually changed from 6.0mm to 1.2mm from the root part of the front edge plate to the root part of the rear edge plate; the maximum 1.0mm of the left edge of the blade body is increased to 5.0mm, and then gradually changed to 1.0 mm. The thickness of the front edge plate and the rear edge plate is 3.6 mm. The local thickening and strengthening of the assembling and connecting area of the front edge plate are realized, and the thickness of the thickening area is 24 mm; a metal embedded sleeve is arranged in the connecting area, and the metal embedded sleeve and the front edge plate are integrally formed. The abrasion-resistant wrapping edges are made of polyimide, and the metal embedded sleeves are made of aluminum alloy.
The forming method of the stator blade made of the variable-thickness composite material comprises the following steps:
1) the outer shape surface of the blade body of the stator blade is a net-size non-processing surface, the forming die is designed to be a combined die of a closed die cavity 4-piece combined die, front and rear edge plate paving areas are reserved on two sides of the upper and lower end face dies of the blade body, 4 corners are designed to be conical guide limiting, and the upper and lower end face dies are ensured not to deviate after being matched; meanwhile, the front and rear edge plate side molds are designed to be conical matching surfaces, and a compaction in-place step is reserved to ensure that the front and rear edge plate side molds are pressed and attached to the designed position; the material of the die is preferably Q235 steel;
2) according to the structural characteristics of the blade and the requirements of the pneumatic profile, a net volume filling method is adopted, according to the extracted neutral surface of the blade body, the thickness of each position of the target blade and the thickness of a single layer of the prepreg are adopted, and the three-dimensional solid surface and the side line profile of each laid prepreg block layer, which are consistent with the total thickness of different areas of the blade body, are designed in a simulated mode; two groups of 36 layers of material block boundaries are obtained according to the volumes of two sides of the neutral plane of the blade body;
3) converting the edge line profile of each layer of material blocks into a two-dimensional graph, and arranging the two-dimensional graph from large to small according to the edge line of the graph; then combining the characteristics of the edge plate and a quasi-isotropic layering sequence design principle to obtain a layering sequence design of each material block layer in the volumes of two sides of the neutral surface of the blade body and cutting a continuous fiber prepreg block of the integral blade;
4) Laying the cut prepreg blocks on working surfaces of dies on the upper end surface and the lower end surface of the leaf body according to the positioning reference line by taking parting lines on the two sides of the leaf body as the positioning reference line, vacuumizing and compacting each 3-5 layers of the prepreg blocks, and closing the dies after paving and pasting the prefabricated body to obtain the prefabricated body of the leaf body;
5) taking the obtained prefabricated body of the blade body out of the die, attaching the edge-covering cut according to the size to the windward side of the prefabricated blade body, and then putting the prefabricated blade body into the upper and lower end dies of the blade body to close the die and compact the die;
6) paving two layers of prepreg blocks on a front edge plate side mold according to the paving sequence, then laminating the corresponding prepreg blocks according to the thickness and size requirements of a connection area, and carrying out glue suction in a hot pressing tank or a hot pressing machine, wherein the glue suction temperature is 70 ℃, the glue suction time is 30min, and the pressure in the hot pressing tank is 0.6 Mpa; after the glue is absorbed and compacted, paving and pasting the prepreg on the front edge plate side mold, and finishing paving and pasting of the residual prepreg blocks; embedding the metal embedded sleeve in the paved connecting area; paving and pasting prepreg blocks on the rear edge plate side mold according to the paving sequence;
7) attaching the front edge plate obtained in the step 6) to the position of the front edge plate after die assembly in the step 5), positioning and compacting; and then attaching the rear edge plate side mold subjected to layering to the position of the rear edge plate subjected to mold closing in the step 5) to complete layering of the integral blade.
8) Curing the product to be cured obtained in the step 7) by coating an auxiliary material in an autoclave or a hot press, wherein the curing temperature is 125 ℃, the curing time is 5 hours, and the curing pressure is 0.8 Mpa; and co-curing preparation of the embedded part and the blade body is realized by adopting a hot pressing process, so that the prepared composite material stator blade is obtained.
9) And (4) processing the allowance edge materials of the front edge plate and the rear edge plate of the solidified stator blade so as to meet the size design requirement of the blade.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention, and those skilled in the art can make variations and modifications of the present invention without departing from the spirit and scope of the present invention by using the methods and technical contents disclosed above.
Claims (9)
1. A variable-thickness composite stator blade forming method comprises a front edge plate, a variable-thickness blade body and a rear edge plate; the variable-thickness blade body is positioned between the front edge plate and the rear edge plate, the front edge plate, the variable-thickness blade body and the rear edge plate are made of the same composite material and are integrally formed, and the windward side of the blade body is protected by a wear-resistant non-metal edge; the method is characterized by comprising the following steps:
1) The outer shape surface of the blade body of the stator blade is a net-size non-processing surface, and the forming die is designed to be a combined die of a closed die cavity 4-piece combined module, wherein front and rear edge plate paving areas are reserved on two sides of the upper and lower end face dies of the blade body, 4 corners are designed to be conical guide limiting, and the upper and lower end face dies of the blade body are ensured not to deviate after being matched; meanwhile, the front and rear edge plate side molds are designed to be conical matching surfaces, and a compaction in-place step is reserved to ensure that the front and rear edge plate side molds are pressed and attached to the designed position;
2) according to the structural characteristics of the blade and the requirements of a pneumatic profile, a net volume filling method is adopted, and according to the extracted neutral surface of the blade body, a three-dimensional solid surface and a sideline outline of each laid continuous fiber prepreg layer, which are consistent with the total thickness of different areas of the blade body, are designed in a simulated mode;
3) converting the side line outline of each laid continuous fiber prepreg layer obtained in the step 2) into a two-dimensional graph, and arranging the two-dimensional graph from large to small according to the side line of the graph; then, the continuous fiber prepreg block of the integral blade is designed and cut by combining the characteristics of the front edge plate and the rear edge plate and the layering symmetry principle;
4) laying the continuous fiber prepreg block cut in the step 3) on the working surfaces of the upper and lower end face dies of the leaf body by taking parting lines on two sides of the leaf body as positioning reference lines, and closing the dies after the continuous fiber prepreg block is laid and attached to obtain a leaf body prefabricated body;
5) Taking the blade body prefabricated body obtained in the step 4) out of the mold, attaching the edge-covering cut according to the size to the windward side of the blade body prefabricated body, and then putting the blade body prefabricated body into the upper end surface mold and the lower end surface mold for mold closing and compaction;
6) paving at least two layers of continuous fiber prepreg blocks on the front edge plate side mold according to the paving sequence, compacting the corresponding continuous fiber prepreg block laminating layer and the adhesive according to the thickness and size requirements of the connecting area of the front edge plate, paving the continuous fiber prepreg blocks on the front edge plate side mold, and finishing paving and pasting the residual continuous fiber prepreg blocks; embedding the metal embedded sleeve in the paved connecting area; paving and sticking continuous fiber prepreg blocks on a rear edge plate side mold according to a paving sequence;
7) attaching the front edge plate side mold obtained in the step 6) to the position of the front edge plate after the mold closing in the step 5), and positioning and compacting; then attaching the rear edge plate side mold subjected to layering to the position of the rear edge plate subjected to mold closing in the step 5) to complete layering of the integral blade;
8) coating auxiliary materials on the outer sides of the front edge plate side die and the rear edge plate side die in the integral blade paving layer in the step 7), and realizing co-curing preparation of the integral blade by adopting a hot pressing process;
9) and processing the allowance rim charge of the front edge plate and the rear edge plate of the solidified stator blade so as to meet the size design requirement of the blade.
2. The method of claim 1, wherein: the glue absorption in the step 6) is carried out in an autoclave or a hot press, the glue absorption temperature is 60-80 ℃, the glue absorption time is 20-40 min, and the pressure in the autoclave is 0.3-0.6 MPa; and vacuumizing the continuous fiber prepreg block to be subjected to glue suction in the glue suction process.
3. The method of claim 1, wherein: and step 8) the curing process in the co-curing preparation of the integral blade by adopting the hot pressing process is carried out in an autoclave or a hot pressing machine, the curing temperature is 120-130 ℃ or 165-180 ℃, the curing time is 3-6 h, and the pressure in the autoclave is 0.6-1.0 MPa.
4. The method of claim 1, wherein: the manufacturing materials of the front edge plate, the blade body and the rear edge plate are all carbon fiber fabric reinforced and toughened epoxy resin composite materials.
5. The method of claim 4, wherein: the carbon fiber is T700, T800, T100 or M40J grade carbon fiber, the form of the carbon fiber fabric comprises plain weave, twill, five satins or eight sandflies, and the resin mass content of the epoxy resin composite material is 38-48%.
6. The method of claim 1, wherein: the local thickening of the assembly connection area of the front edge plate is enhanced, a metal embedded sleeve is arranged in the connection area, and the metal embedded sleeve and the front edge plate are integrally formed.
7. The method of claim 6, wherein: the pre-buried sleeve is made of aluminum alloy or titanium alloy.
8. The method of claim 1, wherein: the non-metal edge covering material is polyurethane or polyimide.
9. The method of claim 1, wherein: the variable thickness composite stator blade is suitable for aeroengines.
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| CN111186149A (en) * | 2019-12-13 | 2020-05-22 | 中国航空制造技术研究院 | Forming device and method for torsion variable-thickness composite material structure |
| CN113043568B (en) * | 2019-12-26 | 2022-05-17 | 中国科学院宁波材料技术与工程研究所 | Prepreg hot-melting infiltration mold |
| CN111664124B (en) * | 2020-06-05 | 2022-07-26 | 中国航发沈阳发动机研究所 | Stator structure, rotor and stator assembly structure with same and assembly method of rotor and stator assembly structure |
| CN112453513B (en) * | 2020-10-14 | 2022-07-12 | 沈阳透平机械股份有限公司 | Method for machining impeller blade of centrifugal compressor and impeller blade |
| CN112592187B (en) * | 2020-12-14 | 2022-05-13 | 西安鑫垚陶瓷复合材料有限公司 | Aviation blade forming tool and technology based on carbon ceramic material |
| CN114559680A (en) * | 2022-01-27 | 2022-05-31 | 武汉海威船舶与海洋工程科技有限公司 | Autoclave forming die and forming method for ship propeller composite material blade |
| CN114800797A (en) * | 2022-05-19 | 2022-07-29 | 西北工业大学 | Multipurpose mold and application thereof |
| CN115302815B (en) * | 2022-10-11 | 2022-12-20 | 江苏新扬新材料股份有限公司 | Manufacturing method of special-shaped airplane frame upright post |
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| US4594761A (en) * | 1984-02-13 | 1986-06-17 | General Electric Company | Method of fabricating hollow composite airfoils |
| US5375978A (en) * | 1992-05-01 | 1994-12-27 | General Electric Company | Foreign object damage resistant composite blade and manufacture |
| US5509781A (en) * | 1994-02-09 | 1996-04-23 | United Technologies Corporation | Compressor blade containment with composite stator vanes |
| CN100497890C (en) * | 2007-09-06 | 2009-06-10 | 东方电气集团东方汽轮机有限公司 | Variable-speed turbine final stage moving vane |
| CN104690982B (en) * | 2013-12-10 | 2018-02-02 | 惠阳航空螺旋桨有限责任公司 | A kind of composite stator blade of engine and preparation method thereof |
| WO2016075619A1 (en) * | 2014-11-10 | 2016-05-19 | Polytech A/S | Polyurethane material, process for preparing such material and protective cover for wind turbine blade |
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