CN110843236A - Preparation method of carbon fiber composite hollow blade - Google Patents
Preparation method of carbon fiber composite hollow blade Download PDFInfo
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- CN110843236A CN110843236A CN201911166565.6A CN201911166565A CN110843236A CN 110843236 A CN110843236 A CN 110843236A CN 201911166565 A CN201911166565 A CN 201911166565A CN 110843236 A CN110843236 A CN 110843236A
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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
- B29C70/345—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 matched moulds
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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
-
- 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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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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
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention provides a preparation method of a carbon fiber composite hollow blade, and belongs to the technical field of part processing. When the hollow blade to be processed is prepared by the method, the resin-based composite material with the thermoplastic material wrapped on the surface is made into the core mold, the first layer is paved on the surface of the core mold, and the base mold and the upper cover plate mold are respectively paved to form a second layer and a third layer, so that the first layer is positioned between the second layer and the third layer, and then the layers are cured to form the hollow blade to be processed; the core mold is softened and is easier to deform, so that the demolding can be realized more conveniently and quickly, and the risk of damaging the hollow blade to be processed in the demolding process is reduced; the shape of the core mold is restored to the initial state by performing shape restoration treatment on the core mold after demolding, so that the core mold can be reused, and the production cost is reduced.
Description
Technical Field
The invention relates to the technical field of part processing, in particular to a preparation method of a carbon fiber composite hollow blade.
Background
The mold is important in the traditional manufacturing industry, the traditional mold is usually made of metal and structurally comprises a female mold, a male mold and a core mold, the female mold, the male mold and the core mold are matched to form a cavity with the shape consistent with that of the hollow blade to be processed, and raw materials are injected into the cavity to form the hollow blade to be processed. In order to facilitate the separation of the hollow blade to be processed from the mold, the core mold is generally designed in a partitioning or splitting manner, so that the mold release is realized after the molding without damaging the hollow blade to be processed. With the continuous progress of the technology, people have higher and higher requirements on the precision and the complexity of the die, the problems of difficult core die demoulding, poor corrosion resistance and the like are shown in the traditional die manufacturing, and the die needs to be disassembled and combined during use, so that the cost is high, and the efficiency is low.
Disclosure of Invention
The invention aims to provide a preparation method of a carbon fiber composite hollow blade, which can conveniently and quickly realize demoulding and reduce the risk of damaging the hollow blade to be processed in the demoulding process; and the core die can be reused after being treated, and has good corrosion resistance.
In order to achieve the above object, the present invention provides the following technical solutions:
the invention provides a preparation method of a carbon fiber composite hollow blade, which comprises the following steps:
(1) wrapping a thermoplastic material on the surface of a resin-based composite material to prepare a core mold of a hollow blade mold to be processed, and laying a carbon fiber fabric prepreg on the surface of the core mold to form a first laying layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; arranging a sealing ring along the edge of the base mold, and then inversely assembling the upper cover plate mold paved with the third paving layer on the base mold paved with the second paving layer, wherein the third paving layer is in contact with one surface of the first paving layer far away from the second paving layer;
(2) curing the first layer, the second layer and the third layer in the hollow blade mould to be processed obtained in the step (1) to cure the first layer, the second layer and the third layer to form the carbon fiber composite hollow blade;
(3) softening the core mold of the hollow blade mold to be processed obtained in the step (2), separating the softened core mold from the carbon fiber composite hollow blade, and performing shape recovery treatment on the softened core mold.
Preferably, the hollow blade mould to be processed in the step (1) is pretreated before being used, and the pretreatment comprises the following steps: cleaning the surface of a core mold of a hollow blade mold to be processed, and then paving demolding cloth; cleaning a base mold and an upper cover plate mold of a hollow blade mold to be processed, and then coating a release agent.
Preferably, step (1) further comprises, after the laying is completed: and carrying out vacuum compaction treatment on the first, second and third laminates.
Preferably, the step (2) further comprises, before the curing treatment: and establishing a vacuum system on the hollow blade mould to be processed in a sealed state, wherein the hollow blade mould to be processed is paved with a first paving layer, a second paving layer and a third paving layer.
Preferably, the method of establishing the vacuum system comprises: and vacuumizing the to-be-processed hollow blade mold in the sealed state until the vacuum degree in the to-be-processed hollow blade mold meets a preset vacuum condition.
Preferably, the vacuum pumping treatment further comprises the following steps of after the vacuum degree in the hollow blade mold to be processed meets the preset vacuum condition: and detecting the vacuum leakage amount of the hollow blade mould to be processed in a preset time, and determining that the establishment of the vacuum system is finished if the vacuum leakage amount is less than or equal to the preset leakage amount.
Preferably, the curing treatment in step (2) comprises a heat and/or pressure treatment.
Preferably, the softening treatment in the step (3) includes a heating treatment, and the temperature of the heating treatment is lower than the glass transition temperature of the carbon fiber composite hollow blade.
Preferably, the shape recovery process in step (3) includes: the softened core mold is placed in a shape recovery mold, and heat and pressure treatment is performed.
Preferably, after the softened core mold is separated from the carbon fiber composite hollow blade in the step (3), a carbon fiber composite sealing block is bonded to an opening of a blade tenon of the carbon fiber composite hollow blade.
The invention provides a preparation method of a carbon fiber composite hollow blade, which comprises the following steps: (1) wrapping a thermoplastic material on the surface of a resin-based composite material to prepare a core mold of a hollow blade mold to be processed, and laying a carbon fiber fabric prepreg on the surface of the core mold to form a first laying layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; arranging a sealing ring along the edge of the base mold, and then inversely assembling the upper cover plate mold paved with the third paving layer on the base mold paved with the second paving layer, wherein the third paving layer is in contact with one surface of the first paving layer far away from the second paving layer; (2) curing the first layer, the second layer and the third layer in the hollow blade mould to be processed obtained in the step (1) to cure the first layer, the second layer and the third layer to form the carbon fiber composite hollow blade; (3) softening the core mold of the hollow blade mold to be processed obtained in the step (2), separating the softened core mold from the carbon fiber composite hollow blade, and performing shape recovery treatment on the softened core mold. When the hollow blade to be processed is prepared by adopting the method provided by the invention, the resin-based composite material with the thermoplastic material wrapped on the surface is made into the core mould, the first layer is paved on the surface of the core mould, and the base mould and the upper cover plate mould are respectively paved to form a second layer and a third layer, so that the first layer is positioned between the second layer and the third layer, and then all layers (namely the first layer, the second layer and the third layer) are cured to form the hollow blade to be processed; the core mold is softened and is easier to deform, so that the demolding can be realized more conveniently and quickly, and the risk of damaging the hollow blade to be processed in the demolding process is reduced; the shape of the core mold is restored to the initial state by performing shape restoration treatment on the core mold after demolding, so that the core mold can be reused, and the production cost is reduced.
Drawings
FIG. 1 is a schematic perspective view of a carbon fiber composite hollow blade according to the present invention;
FIG. 2 is a schematic perspective view of a core mold of a hollow blade mold to be processed according to the present invention from a first perspective (including end caps);
FIG. 3 is a schematic perspective view of a second perspective view of a core mold (including end caps) of a hollow blade mold to be processed according to the present invention;
FIG. 4 is a schematic perspective view of an upper cover plate mold in a mold for manufacturing a hollow blade to be processed according to the present invention;
FIG. 5 is a schematic diagram showing the positional relationship between a base mold and a sealing ring in a mold for manufacturing a hollow blade to be processed according to the present invention;
FIG. 6 is a flowchart of the production of a carbon fiber composite hollow blade in example 1 of the present invention;
FIG. 7 is a graph showing the operation of the autoclave in accordance with the present invention in example 1;
FIG. 8 is a flowchart of the production of a carbon fiber composite hollow blade in example 2 of the present invention;
FIG. 9 is a flowchart of the production of a carbon fiber composite hollow blade in example 3 of the present invention;
FIG. 10 is a flowchart of production of a carbon fiber composite hollow blade in example 3 of the present invention;
in the figure, 10-mandrel; 11-end cap; 20-base mold; 30-a sealing ring; 40-upper cover plate mould; 50-carbon fiber composite hollow blade.
Detailed Description
The invention provides a preparation method of a carbon fiber composite hollow blade, which comprises the following steps:
(1) wrapping a thermoplastic material on the surface of a resin-based composite material to prepare a core mold of a hollow blade mold to be processed, and laying a carbon fiber fabric prepreg on the surface of the core mold to form a first laying layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; arranging a sealing ring along the edge of the base mold, and then inversely assembling the upper cover plate mold paved with the third paving layer on the base mold paved with the second paving layer, wherein the third paving layer is in contact with one surface of the first paving layer far away from the second paving layer;
(2) curing the first layer, the second layer and the third layer in the hollow blade mould to be processed obtained in the step (1) to cure the first layer, the second layer and the third layer to form the carbon fiber composite hollow blade;
(3) softening the core mold of the hollow blade mold to be processed obtained in the step (2), separating the softened core mold from the carbon fiber composite hollow blade, and performing shape recovery treatment on the softened core mold.
The method comprises the steps of wrapping a thermoplastic material on the surface of a resin-based composite material to prepare a core mold of a hollow blade mold to be processed, and paving a carbon fiber fabric prepreg on the surface of the core mold to form a first paving layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; set up the sealing washer along the edge of base mould, later will lay the upper cover plate mould back-off equipment that the third spread the layer and lay the base mould that the second spread the layer on, just the third is spread the layer and is spread the one side contact that the second spread the layer with first shop. In the invention, the TG temperature of the core mold is preferably less than 100 ℃, and the TG temperature of the finally obtained carbon fiber composite hollow blade is preferably more than or equal to 135 ℃.
In the invention, the hollow blade mould to be processed comprises a core mould, a base mould and an upper cover plate mould, wherein the core mould is arranged between the base mould and the upper cover plate mould, and the base mould can be used for bearing the core mould and the upper cover plate mould on one hand and can be matched with the core mould and the upper cover plate mould to form a forming cavity on the other hand, so that the shape of the hollow blade to be processed formed by laying is consistent with the actual requirement. In the invention, the resin-based composite material used for preparing the core mold is preferably a composite material of carbon fiber and modified epoxy resin, the proportion of the carbon fiber and the modified epoxy resin is not specially limited, and the core mold is ensured to have the required strength. The specific type, size and the like of the carbon fiber are not particularly limited in the present invention, and carbon fibers known to those skilled in the art, such as Dongli T300 carbon fiber, may be used. The TG temperature of the modified epoxy resin is preferably less than 100 ℃, so that the subsequent softening treatment and the shape recovery treatment of the core mold are convenient; the source of the modified epoxy resin is not specially limited, and the modified epoxy resin can meet the TG temperature requirement. The TG temperature of the thermoplastic material used to make the core mold is preferably <100 ℃, the melting point is preferably >200 ℃; the invention does not specially limit the specific types of the thermoplastic materials, and can meet the requirements of the TG temperature and the melting point, such as polyphenylene sulfide (PPS); the thermoplastic material can play an isolation role, and separates the resin matrix composite material in the core mold from a layer formed by the carbon fiber fabric prepreg, so that the layer can be conveniently and smoothly spread for subsequent curing treatment. The invention is not limited to the amount of the thermoplastic material and the specific operation of wrapping the thermoplastic material, and the method can be well known to those skilled in the art.
The method comprises the steps of preparing a resin-based composite material with a thermoplastic material wrapped on the surface into a core mold, paving a first layer on the surface of the core mold, respectively paving a base mold and an upper cover plate mold to form a second layer and a third layer, enabling the first layer to be located between the second layer and the third layer, and then curing the layers (namely the first layer, the second layer and the third layer) to form the hollow blade to be processed; the core mold is softened and is easier to deform, so that the demolding can be realized more conveniently and quickly, and the risk of damaging the hollow blade to be processed in the demolding process is reduced; the shape of the core mold is restored to the initial state by performing shape restoration treatment on the core mold after demolding, so that the core mold can be reused, and the production cost is reduced. Moreover, compared with the traditional metal core mold, the core mold provided by the invention has excellent corrosion resistance.
As an embodiment of the present invention, the hollow blade mold to be processed further includes an end cap provided at one end of the core mold. In the present invention, the base mold 20, the end cap 11, and the upper cover mold 40 are preferably made of stainless steel. The method specifically comprises the steps of determining the shape and the size of a hollow blade mould to be processed according to the shape and the size of the hollow blade made of the required carbon fiber composite material; in the embodiment of the invention, the structure of the carbon fiber composite hollow blade is shown in fig. 1, the three-dimensional structure schematic diagram of the position relationship of the core mold and the end cover is shown in fig. 2 and 3, and the three-dimensional structure schematic diagram of the upper cover plate mold is shown in fig. 4.
In the present invention, the hollow blade mold to be processed is preferably pretreated before use, and the pretreatment preferably includes: cleaning the surface of a core mold of a hollow blade mold to be processed, and then paving demolding cloth; cleaning a base mold and an upper cover plate mold of a hollow blade mold to be processed, and then coating a release agent. The cleaning process can remove impurities such as dust on the surface of the core mold, the base mold and the upper cover plate mold, and avoid the molded hollow blade to be processed from being affected by the impurities contained therein, such as the mechanical property, reliability and the like of the hollow blade to be processed. According to the material of the hollow blade to be processed, the skilled person can adopt the appropriate type of release agent, coating method and coating amount, and select the appropriate release cloth, such as tetrafluoroethylene release cloth, without limitation.
According to the invention, carbon fiber fabric prepreg is laid on the surface of the core mold to form a first paving layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; set up the sealing washer along the edge of base mould, later will lay the upper cover plate mould back-off equipment that the third spread the layer and lay the base mould that the second spread the layer on, just the third is spread the layer and is spread the one side contact that the second spread the layer with first shop. The raw materials and the preparation method for the carbon fiber fabric prepreg are not particularly limited, and the carbon fiber fabric prepreg can be prepared by adopting a conventional method in the field or can be directly prepared from commercial products according to actual needs. In the invention, the TG temperature of the finally obtained carbon fiber composite hollow blade is specifically determined by epoxy resin in the carbon fiber fabric prepreg; the TG temperature of the epoxy resin in the carbon fiber fabric prepreg is preferably more than or equal to 135 ℃; in the embodiment of the invention, the carbon fiber fabric prepreg is specifically Dongli T300 carbon fiber prepreg; the number of piles of the carbon fiber fabric prepreg forming the first layer of laying can be 15-30 layers, the number of piles of the carbon fiber fabric prepreg forming the second layer of laying can be 15-20 layers, the number of piles of the carbon fiber fabric prepreg forming the third layer of laying can be 15-20 layers, and the structural strength of the hollow blade to be processed meets requirements. In the invention, in the laying process, the accuracy of the laying position is preferably controlled by using a laser projector or a laying clamping plate, so that the quality of the hollow blade to be processed is ensured. In the embodiment of the invention, specifically, carbon fiber fabric prepreg is laid around the surface of the core mold for one circle, and is fixed by using an end cover. In the invention, the second layer and the third layer can modify the shape of the carbon fiber composite hollow blade, which is beneficial to improving the quality of the hollow blade to be processed.
In the present invention, after the first, second and third plies are laid, it is preferable that the method further includes: and carrying out vacuum compaction treatment on the first, second and third laminates. The vacuum compaction treatment can discharge gas in the layer, and is favorable for avoiding the influence of bubbles contained in the layer on the structural strength, the mechanical property and the like of the hollow blade to be processed. The first layer, the second layer and the third layer are preferably subjected to vacuum compaction treatment respectively, specifically, a core mold paved with the first layer is placed in a vacuum bag, then gas in the vacuum bag is extracted to remove the gas in the first layer and compact the first layer, the vacuum degree in the vacuum bag is not specially limited, and the gas in the first layer is fully discharged by setting according to actual needs; and respectively placing the base mold paved with the second paving layer and the upper cover plate mold paved with the third paving layer into a vacuum bag according to the method, and carrying out vacuum compaction treatment.
The core mould paved with the first layer is positioned on the base mould paved with the second layer, so that the core mould paved with the first layer is accurately placed on the base mould paved with the second layer, and the machining requirement of precision parts is met.
According to the invention, the sealing ring is arranged along the edge of the base mold (as shown in fig. 5), and then the upper cover plate mold paved with the third paving layer is assembled on the base mold paved with the second paving layer in a reverse buckling manner, so that the hollow blade mold to be processed is in a sealing state.
After a first layer, a second layer and a third layer are formed in a hollow blade mould to be processed, the first layer, the second layer and the third layer in the hollow blade mould to be processed are cured, and the first layer, the second layer and the third layer are cured to form the carbon fiber composite material hollow blade. In the present invention, it is preferable that the curing treatment further comprises: and establishing a vacuum system on the hollow blade mould to be processed in a sealed state, wherein the hollow blade mould to be processed is paved with a first paving layer, a second paving layer and a third paving layer. According to the invention, the vacuum system is established on the sealed hollow blade mould to be processed on which the first layer, the second layer and the third layer are laid, so that bubbles generated in the curing process can be removed, and the quality of the molded hollow blade to be processed is improved. In the present invention, the method of establishing the vacuum system preferably includes: and vacuumizing the to-be-processed hollow blade mold in the sealed state until the vacuum degree in the to-be-processed hollow blade mold meets a preset vacuum condition. Because the sealing ring is arranged between the base mold and the upper cover plate mold, air leakage of a gap between the base mold and the upper cover plate mold can be prevented, the hollow blade mold to be processed is in a sealing state, the hollow blade mold to be processed in the sealing state can be directly vacuumized, and the internal vacuum degree of the hollow blade mold to be processed meets the preset vacuum condition. In the invention, the preset vacuum condition is preferably that the vacuum degree in the sealed hollow blade mould to be processed is controlled to be less than or equal to-85 kPa, and bubbles generated in the curing process can be quickly and fully removed under the vacuum degree condition, so that the quality of the molded hollow blade to be processed is improved.
In order to ensure that the vacuum degree in the vacuum system can meet the required requirements and further ensure the quality of the hollow blade to be processed, the vacuum-pumping treatment in the invention preferably further comprises the following steps after the vacuum degree in the hollow blade mould to be processed meets the preset vacuum condition: and detecting the vacuum leakage amount of the hollow blade mould to be processed in a preset time, and determining that the establishment of the vacuum system is finished if the vacuum leakage amount is less than or equal to the preset leakage amount. Wherein the preset time can be 1min, 5min or 10min, and the like, and can be determined by a person skilled in the art as required; the predetermined amount of leakage may be 17kPa, taking the predetermined time as 5min for example.
The method comprises the steps of curing a first layer, a second layer and a third layer in a hollow blade mould to be processed to form the carbon fiber composite hollow blade through curing; the curing treatment preferably comprises heating and/or pressurizing treatment, the curing treatment is preferably carried out in an autoclave, specifically, a hollow blade mold to be processed, in which a first layer, a second layer and a third layer are paved, is conveyed into the autoclave, and the first layer, the second layer and the third layer are cured under the heating and/or pressurizing condition to form the carbon fiber composite hollow blade. According to the invention, the autoclave is preferably adjusted to proper temperature and/or pressure according to different layering materials, so that the layering can be solidified to form the hollow blade to be processed; specifically, after the hollow blade mould to be processed is conveyed into the autoclave, according to the characteristics of the paving material, a working curve of the autoclave, the temperature and/or the pressure of which change along with time, is set, the autoclave is enabled to work according to the set curve to provide heating and/or pressurizing conditions, so that the curing reliability is ensured, and the structural strength of the molded hollow blade to be processed can meet the requirement. It should be noted that, for different hollow blades to be processed, the used layer materials may be different, and accordingly, the set working curves of the temperature and/or pressure of the heating tank changing with time may also be different, for example, the temperature may be 20 to 180 ℃, and the pressure may be 0.1 to 0.7 MPa.
In the invention, when the temperature is higher than 100 ℃ in the curing process during the preparation of the carbon fiber composite hollow blade, the core mold with the TG temperature lower than 100 ℃ can be softened, and the core mold can expand after being softened, so that the paving layer can be attached to the outer side base mold and the upper cover plate mold, namely, the base mold and the upper cover plate mold are utilized to ensure that the hollow blade to be processed has the required shape on the basis of the core mold.
After the solidification treatment is finished, the core mold of the hollow blade mold to be processed is softened, then the softened core mold is separated from the carbon fiber composite material hollow blade, and the softened core mold is subjected to shape recovery treatment. After the hollow blade to be processed is solidified and formed, in order to enable the demoulding to be quicker and more convenient and not to damage the formed hollow blade to be processed, the invention enables the core mould to be deformed by softening the core mould, thereby separating the core mould from the hollow blade to be processed and completing the demoulding. In the present invention, when the softening treatment is performed, an appropriate treatment method can be selected and softened according to the material of the core mold. For example, the core mold may be softened by applying a heat treatment to the core mold, wherein the temperature of the heat treatment is lower than the glass transition temperature of the separation of the hollow blade to be processed, thereby ensuring that the hollow blade to be processed is not damaged by the heat.
After the softened core mold is separated from the carbon fiber composite hollow blade, the shape of the softened core mold is recovered; the shape recovery process preferably includes: putting the softened core mold into a shape recovery mold, and heating and pressurizing; preferably, the core mould is aerated with hot air by an electric heating blower, so that heating and pressurizing treatment can be realized; the temperature of the hot air is preferably 85-100 ℃, and more preferably 100 ℃; the pressure is preferably more than 0.1MPa, and more preferably 0.2-0.4 MPa; the time for introducing the hot air is preferably 5-15 min, and more preferably 10 min. In the present invention, the shape recovery mold has a groove for receiving the core mold, the groove having a shape corresponding to an original shape of the core mold, and the shape of the core mold is gradually recovered to the shape of the groove, that is, the original shape, during heating and pressing of the core mold, so that the recovered core mold can be reused; therefore, the utilization rate of the core mold can be improved, and the core mold can be repeatedly used for 50-80 times, so that the production cost is reduced.
After the softened core mold is separated from the carbon fiber composite hollow blade, the carbon fiber composite sealing block is preferably bonded to the blade tenon tooth opening of the carbon fiber composite hollow blade, so that the overall performance of the carbon fiber composite hollow blade is enhanced, and the structural strength of the carbon fiber composite hollow blade is improved. The present invention is not limited to the specific manner of the adhesive bonding, and the adhesive bonding may be performed in a manner known to those skilled in the art. In the invention, the material of the carbon fiber composite sealing block is preferably consistent with that of the carbon fiber composite hollow blade.
The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
Referring to the flow shown in fig. 6, the carbon fiber composite hollow blade is prepared, which comprises the following steps:
step S102: the hollow blade mold to be processed comprises an upper cover plate mold 40, a base mold 20, a core mold 10 arranged between the upper cover plate mold 40 and the base mold 20, and an end cover 11 arranged at one end of the core mold 10; the core mold 10 is formed by wrapping a thermoplastic material on the surface of a resin-based composite material, wherein the resin-based composite material is a composite material of Dongli T300 carbon fiber and modified epoxy resin (TG temperature <100 ℃), and the thermoplastic material is polyphenylene sulfide (PPS); the upper cover plate mould 40, the base mould 20 and the end cover 11 are all made of stainless steel;
laying 20 layers of carbon fiber fabric prepreg (Dongli T300 carbon fiber prepreg, wherein the TG temperature of epoxy resin is 135 ℃) on the surface of the core mold 10 in a laminated manner (laying is carried out by surrounding the surface of the core mold 10 for one circle) to form a first laying layer, and fixing the first laying layer by adopting an end cover 11;
laying 15 layers of carbon fiber fabric prepreg (Dongli T300 carbon fiber prepreg, wherein the TG temperature of epoxy resin is 135 ℃) on a base mold 20 of a hollow blade mold to be processed in a laminated manner to form a second laying layer;
laying 15 layers of carbon fiber fabric prepreg (Dongli T300 carbon fiber prepreg, wherein the TG temperature of epoxy resin is 135 ℃) on an upper cover plate mould 40 of a hollow blade mould to be processed in a laminated manner to form a third laying layer;
positioning the core mold 10 laid with the first ply onto a base mold 20 laid with a second ply in contact with one face of the first ply; arranging a sealing ring along the edge of the base mold 20, and then inversely assembling the upper cover plate mold 40 paved with the third paving layer on the base mold 20 paved with the second paving layer, wherein the third paving layer is in contact with one surface of the first paving layer far away from the second paving layer;
step S104: conveying the hollow blade mould to be processed into an autoclave, heating and pressurizing the autoclave to solidify and mold the first layer, the second layer and the third layer and form the hollow blade to be processed, wherein the pressure of the autoclave is 0.3MPa, and the working curve of the temperature changing along with time is shown in FIG. 7;
step S106: heating the core mold 10 of the hollow blade mold to be processed to 100 ℃ to soften and deform the core mold, and then separating the softened core mold 10 from the hollow blade to be processed to finish demolding;
step S108: the softened core mold 10 is put into a shape recovery mold, and hot air is blown into the core mold by an electric heating blower to perform heating and pressurizing treatment (the temperature of the hot air is 100 ℃, the pressure is 0.3MPa, and the time for blowing the hot air is 10min) so that the shape of the softened core mold 10 is recovered to an initial state, thereby facilitating the reuse of the core mold 10.
Example 2
Referring to the flow shown in fig. 8, a carbon fiber composite hollow blade is prepared, which is different from embodiment 1 in that step S102 includes the following substeps:
substep S1021: cleaning the surface of a core mold 10 of a hollow blade mold to be processed, and then paving demolding cloth (specifically tetrafluoroethylene demolding cloth); cleaning a base mold 20 and an upper cover plate mold 40 of a hollow blade mold to be processed, and then coating a release agent;
substep S1022: laying carbon fiber fabric prepreg on the surface of the core mold 10 by using a laser projector to form a first laying layer; placing the core mould 10 with the first layer laid thereon into a vacuum bag, and then extracting gas in the vacuum bag to remove the gas in the first layer and compact the first layer;
substep S1023: laying carbon fiber fabric prepreg on the base mold 20 by using a laser projector to form a second laying layer; placing the base mold 20 paved with the second paving layer into a vacuum bag, and then extracting gas in the vacuum bag to remove the gas in the second paving layer and compact the second paving layer;
substep S1024: laying carbon fiber fabric prepreg on the upper cover plate mould 40 by using a laser projector to form a third laying layer; placing the upper cover plate mould 40 paved with the third layer into a vacuum bag, and then extracting gas in the vacuum bag to remove the gas in the third layer and compact the third layer;
substeps S1022, substep S1023 and substep S1024 are not defined in chronological order.
Example 3
Referring to the flow shown in fig. 9, a carbon fiber composite hollow blade is prepared, which is different from embodiment 1 in that after step S102 and before step S104, the method further includes the following steps:
step S104 a: establishing a vacuum system on a hollow blade mould to be processed in a sealed state, wherein a first layer, a second layer and a third layer are laid on the hollow blade mould; the method specifically comprises the steps of vacuumizing a to-be-processed hollow blade mould in a sealed state until the vacuum degree in the to-be-processed hollow blade mould is-85 kPa, then detecting the vacuum leakage of a vacuum system, and determining that the establishment of the vacuum system is finished if the leakage is less than or equal to 17kPa in 5 min.
Example 4
Referring to the flow shown in fig. 10, a carbon fiber composite hollow blade is prepared, which is different from embodiment 1 in that step S106 is followed by step S110: after demolding, adhering a carbon fiber composite material sealing block to an opening of a blade tenon tooth of the hollow blade to be processed;
step S108 and step S110 are not limited in chronological order.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (10)
1. The preparation method of the carbon fiber composite hollow blade is characterized by comprising the following steps of:
(1) wrapping a thermoplastic material on the surface of a resin-based composite material to prepare a core mold of a hollow blade mold to be processed, and laying a carbon fiber fabric prepreg on the surface of the core mold to form a first laying layer; laying a carbon fiber fabric prepreg on a base mold of a hollow blade mold to be processed to form a second laying layer; laying a carbon fiber fabric prepreg on an upper cover plate mould of the hollow blade mould to be processed to form a third laying layer; positioning a core mold paved with a first layer on a base mold paved with a second layer, wherein the second layer is in contact with one surface of the first layer; arranging a sealing ring along the edge of the base mold, and then inversely assembling the upper cover plate mold paved with the third paving layer on the base mold paved with the second paving layer, wherein the third paving layer is in contact with one surface of the first paving layer far away from the second paving layer;
(2) curing the first layer, the second layer and the third layer in the hollow blade mould to be processed obtained in the step (1) to cure the first layer, the second layer and the third layer to form the carbon fiber composite hollow blade;
(3) softening the core mold of the hollow blade mold to be processed obtained in the step (2), separating the softened core mold from the carbon fiber composite hollow blade, and performing shape recovery treatment on the softened core mold.
2. The preparation method according to claim 1, wherein the hollow blade mold to be processed in the step (1) is pretreated before use, and the pretreatment comprises the following steps: cleaning the surface of a core mold of a hollow blade mold to be processed, and then paving demolding cloth; cleaning a base mold and an upper cover plate mold of a hollow blade mold to be processed, and then coating a release agent.
3. The method for preparing according to claim 1, wherein the laying in step (1) is completed by further comprising: and carrying out vacuum compaction treatment on the first, second and third laminates.
4. The method according to claim 1, wherein the step (2) further comprises, before the curing treatment: and establishing a vacuum system on the hollow blade mould to be processed in a sealed state, wherein the hollow blade mould to be processed is paved with a first paving layer, a second paving layer and a third paving layer.
5. The method of manufacturing according to claim 4, wherein the method of establishing the vacuum system includes: and vacuumizing the to-be-processed hollow blade mold in the sealed state until the vacuum degree in the to-be-processed hollow blade mold meets a preset vacuum condition.
6. The preparation method according to claim 5, wherein the vacuumizing until the vacuum degree in the hollow blade mold to be processed meets a preset vacuum condition further comprises: and detecting the vacuum leakage amount of the hollow blade mould to be processed in a preset time, and determining that the establishment of the vacuum system is finished if the vacuum leakage amount is less than or equal to the preset leakage amount.
7. The production method according to claim 1, wherein the curing treatment in step (2) includes a heating and/or pressing treatment.
8. The production method according to claim 1, wherein the softening treatment in step (3) includes a heating treatment at a temperature lower than the glass transition temperature of the carbon fiber composite hollow blade.
9. The production method according to claim 1, wherein the shape recovery process in step (3) includes: the softened core mold is placed in a shape recovery mold, and heat and pressure treatment is performed.
10. The preparation method according to claim 1, wherein after the softened core mold is separated from the carbon fiber composite hollow blade in the step (3), a carbon fiber composite sealing block is bonded to an opening of a blade tenon of the carbon fiber composite hollow blade.
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