CN112776371A - Preparation method of wind tunnel blade - Google Patents
Preparation method of wind tunnel blade Download PDFInfo
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- CN112776371A CN112776371A CN202110014081.0A CN202110014081A CN112776371A CN 112776371 A CN112776371 A CN 112776371A CN 202110014081 A CN202110014081 A CN 202110014081A CN 112776371 A CN112776371 A CN 112776371A
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- petiole
- electric heating
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- blade
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- 238000002360 preparation method Methods 0.000 title claims abstract description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 87
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 78
- 239000006260 foam Substances 0.000 claims abstract description 71
- 239000002184 metal Substances 0.000 claims abstract description 48
- 229910052751 metal Inorganic materials 0.000 claims abstract description 48
- 238000004519 manufacturing process Methods 0.000 claims abstract description 34
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 27
- 239000004917 carbon fiber Substances 0.000 claims abstract description 27
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000004744 fabric Substances 0.000 claims abstract description 26
- 238000005520 cutting process Methods 0.000 claims abstract description 13
- 239000011152 fibreglass Substances 0.000 claims abstract description 7
- 238000000465 moulding Methods 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 116
- 238000005485 electric heating Methods 0.000 claims description 86
- 239000003365 glass fiber Substances 0.000 claims description 25
- 238000010438 heat treatment Methods 0.000 claims description 18
- 239000011241 protective layer Substances 0.000 claims description 15
- 239000012528 membrane Substances 0.000 claims description 13
- 239000002238 carbon nanotube film Substances 0.000 claims description 10
- 239000002041 carbon nanotube Substances 0.000 claims description 9
- 229910021393 carbon nanotube Inorganic materials 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 9
- 238000009434 installation Methods 0.000 claims description 8
- 238000009413 insulation Methods 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 4
- 238000005056 compaction Methods 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 238000010097 foam moulding Methods 0.000 claims description 3
- 210000003462 vein Anatomy 0.000 claims description 3
- 238000007731 hot pressing Methods 0.000 claims description 2
- 238000005086 pumping Methods 0.000 claims description 2
- 239000000835 fiber Substances 0.000 abstract description 3
- 230000000149 penetrating effect Effects 0.000 abstract description 2
- 239000000945 filler Substances 0.000 abstract 1
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 235000004443 Ricinus communis Nutrition 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
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Classifications
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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
-
- 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
-
- 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
- B29L2031/085—Wind turbine blades
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Moulding By Coating Moulds (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
The invention discloses a preparation method of a wind tunnel blade, which comprises the following steps of cutting carbon fiber prepreg cloth or prepreg glass fiber reinforced plastic fiber cloth for manufacturing a skin, a filler strip, a foam core and a metal blade stalk; manufacturing a carbon beam by using a carbon beam mold: the carbon beam mold comprises a base and a special-shaped strip mold fixed on the base; inserting a petiole into a petiole mounting groove of a carbon beam mold, sleeving cut carbon fiber prepreg cloth on the metal petiole in a penetrating manner, paving the metal petiole in an end face where a connecting waist of the petiole flat block is positioned and front and rear layer laying grooves of the carbon beam mold, vacuumizing and compacting 15-20 layers each time, and finally taking down the carbon fiber prepreg cloth and the petiole together from the mold after integrally vacuumizing and compacting; inserting the metal petiole into the groove for accommodating the petiole in the foam core, laying the carbon beam in the upper and lower accommodating grooves of the foam core, laying each layer of the covering layer, and finally curing and molding at the temperature of 130-180 ℃ in the autoclave. The wind tunnel petiole, the foam core and the carbon beam manufactured by the invention have high connection strength, high layering density and long service life.
Description
Technical Field
The invention belongs to the technical field of wind tunnel compressors, and relates to a preparation method of a wind tunnel blade.
Background
The wind tunnel is a basic device for carrying out aerodynamic tests, when the wind tunnel runs, energy for maintaining gas flow is provided by driving an axial flow fan by a motor, energy consumption of airflow in a wind tunnel pipeline is specifically shown in that pressure is reduced, the axial flow fan is used for improving pressure of the airflow, when the two reach balance, the wind tunnel can stably run, the power of the general wind tunnel is very high, the power of the axial flow fan is required to be very high, otherwise, a large amount of wind energy loss can be caused, and various performance indexes of a test section of the wind tunnel are influenced.
At present, the carbon beam process for manufacturing the metal petiole composite carbon fiber foam core structure blade is to directly lay carbon beam prepreg on the surfaces of the metal petiole and the foam core after the metal petiole is inserted on the foam core, and the defect is that the joint of the steel petiole and the foam core is weak, the foam core at the joint is easy to break after hundreds of times of laying and pressing, so that the fiber laying pressing strength is small in the laying process, the laying is loose, and the density is poor. In addition, no matter the foam core is PMI machine-formed or foam molding, the back edge is very thin, and in the laying prepreg process, the back edge foam often meets the rupture phenomenon, needs to use the glued membrane to bond it fixedly, and work efficiency is low and the fiber laying is not compact. These all result in the low strength of current wind tunnel blade, short service life. In the icing wind tunnel, icing phenomenon can occur on the front edge of the conventional wind tunnel blade in a wet and cold environment, so that the icing can cause large vibration to cause that the test cannot be continued when the icing reaches a certain degree, and meanwhile, equipment in the icing wind tunnel can be damaged due to the falling of ice blocks.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides a preparation method of a wind tunnel blade.
In order to achieve the purpose, the technical solution of the invention is as follows: a preparation method of a wind tunnel blade comprises the following steps:
(1) manufacturing an upper die and a lower die according to the actual shape and size requirements of the blade; cutting 5-10 layers of carbon fiber prepreg or glass fiber prepreg required for manufacturing the skin, and marking, laying and positioning marks; manufacturing cushion strips at the shoulder and the tip of the foam core;
(2) processing the foam core or the foam molding foam core by using foam numerical control processing equipment; the shape of the foam core is the same as that of the blade body of the blade, one end of the foam core, which is provided with a blade handle, is provided with a groove for accommodating the blade handle, the working surface and the non-working surface of the foam core are respectively provided with an upper accommodating groove and a lower accommodating groove of the upper wall and the lower wall of the carbon beam, and two flat bosses are raised on the bottom surface of the groove;
(3) processing the metal petiole by using numerical control processing equipment; one end of the metal blade handle is a hollow cylinder with an installation step on the excircle, the other end of the metal blade handle is a flat block which is completely matched with the groove of the foam core, and a narrow flat connection waist is arranged between the hollow cylinder and the flat block; one end of the flat block, which is far away from the hollow cylinder, is provided with a central lightening hole communicated with the hollow cylinder and boss accommodating grooves which are arranged on two sides of the lightening hole and are completely matched with two bosses of the foam core, and the side surface of the flat block, which is close to the connecting waist, is provided with a wire routing hole of an electric heating unit component communicated with the central lightening hole;
(4) manufacturing a carbon beam by using a carbon beam mold;
A. the carbon beam mold comprises a base and a special-shaped strip mold fixed on the base; the special-shaped long strip die is integrally formed, the lower end part of the special-shaped long strip die is a fixed block, the upper end part of the special-shaped long strip die is provided with a petiole installation groove which is completely matched with the flat block of the metal petiole, and a positioning shaft matched with a central lightening hole of the petiole protrudes from the bottom surface of the petiole installation groove; the part between the fixing block and the petiole mounting groove is provided with a front layer groove and a rear layer groove, and the parts clamped by the front layer groove and the rear layer groove and the front layer groove and the rear layer groove are the same as the parts clamped by the upper holding groove, the lower holding groove, the upper holding groove and the lower holding groove of the foam core in special shape and size; a clamping groove matched with the fixing block at the lower end of the special-shaped strip die is fixed at the center of the upper end face of the base, mounting holes are formed in the fixing block and the wall of the clamping groove, and the fixing block and the wall of the clamping groove are fixed together through the mounting holes;
B. installing a petiole on a foam core, cutting carbon fiber prepreg according to the shape and the size of the spread end surface where the connecting waist of the flat petiole block is located, the upper wall and the lower wall of the flat petiole block and the shape and the size of the upper accommodating groove and the lower accommodating groove of the foam core, opening a connecting hole matched with the flat connecting waist of the metal petiole on the cut carbon fiber prepreg, and marking and laying a positioning mark; determining the number of cutting layers according to the thickness of the carbon fiber prepreg and the thickness requirements of the upper and lower holding tanks of the foam core;
C. manufacturing a carbon beam; sticking demolding cloth on the front and rear layer laying grooves of the carbon beam mold, inserting the manufactured metal petiole into the petiole mounting groove of the carbon beam mold, and inserting the positioning shaft of the carbon beam mold into the central lightening hole of the metal petiole; then laying the cut carbon fiber prepreg cloth according to the required laying sequence: after a connecting hole of the cut carbon fiber prepreg cloth penetrates through a hollow cylinder of a metal petiole, paving the connecting hole on the end surface where the connecting waist of the flat petiole block is located, the front wall and the rear wall of the flat petiole block and the front and rear layer paving grooves of a carbon beam mold by using a scraper, performing vacuum compaction once when 15-20 layers are paved, and after the paving is performed, performing vacuum compaction once on the whole, taking down the prepared carbon beam and the metal petiole from the mold;
(5) blade forming: inserting the metal petiole coated with the carbon beam into a groove of the foam core for accommodating the petiole, and wrapping and installing the carbon beam in the upper and lower accommodating grooves of the metal petiole and the foam core; laying each layer of carbon fiber prepreg or glass fiber prepreg of the skin in a lower die according to a required laying sequence, then placing the metal petioles, the foam cores and the carbon beams which are arranged together on the inner layer of the skin of the cavity of the lower die, and attaching cushion strips at the shoulders and the tips of the foam cores; wrapping the skin on the metal petiole, the foam core and the carbon beam, and lapping the lower edge of the skin on the upper edge by not less than 30 mm; after the upper die and the lower die are closed, the upper die and the lower die are placed into an autoclave to be cured and molded at the temperature of 130-.
Further preferably, in the step (4) a, universal wheels are respectively fixed to four corners of the carbon beam mold base; the universal wheel is provided with a locking device or not; hoisting holes are formed in the left side face and the right side face of the upper end of the special-shaped strip die. The universal wheel can be twisted flexibly during operation, so that the layer laying of workers is facilitated, and the layer laying efficiency is increased. The carbon beam mold is heavy, and the hoisting holes facilitate hoisting and shifting of the tool.
Further preferably, the method also comprises the step (6), in the step (5), when the skin 1 is laid with the rest 1-2 layers, the semi-finished blade is taken out from the cavity of the lower die, then the semi-finished blade is placed on a tool, the electric heating unit component 4 is wrapped and fixed on the front edge of the blade body, then the semi-finished blade is placed in the cavity of the lower die, the last 1-2 layers of the skin 1 are laid, after the upper die and the lower die are closed, the semi-finished blade is placed in a hot-pressing tank and is cured and molded at the temperature of 130-;
manufacturing an electric heating unit assembly by using an electric heating unit mold:
A. the electric heating unit mould is an integrated piece, the lower end of the electric heating unit mould is a base, and the base is upwards protruded to form a convex mould which is the same as the shape and size of the front edge of the blade body of the blade in the 1-2 layers of the covering; the upper end surfaces of the bases on the left side and the right side of the male die are planes, the perimeter of the working surface end of the male die is the perimeter of the electric heating unit wrapped from the front edge boundary line of the blade body to the working surface end, and the perimeter of the non-working surface end of the male die is the perimeter of the electric heating unit wrapped from the front edge boundary line of the blade body to the non-working surface end; the upper end surfaces of the bases at the front end and the rear end of the convex membrane are curved surfaces and respectively change along with the change of the connecting curves of the two edges of the electric heating unit component and the front edge of the blade body; the widths of the upper end faces of the bases at the left side, the right side, the front end and the rear end of the convex film ensure that the positions left after the paving is finished can still be fixed by fixing the vacuum pumping bag;
B. manufacturing an electric heating unit assembly, and cutting more than two layers of insulating protection layer prepregs according to the overall length requirement of the electric heating unit assembly; laying an insulating protection layer prepreg on a plane workbench, bonding an electric heating element on the insulating protection layer, adding a layer of insulating protection layer prepreg, hermetically wrapping the rest electric heating elements except two wiring terminals of the electric heating element in the insulating protection layer prepreg, and bending to lead the two wiring terminals out from one direction to the bottom to manufacture an electric heating unit; then laying one or more layers of insulating protection layer prepregs on the inner layer on a male die of the electric heating unit die according to the insulation requirement, laying the electric discharge heating unit, and finally laying one or more layers of insulating protection layer prepregs on the outer layer; and (5) vacuumizing and compacting the sleeve sealing bag.
Further preferably, the length of the working face end of the male die is not less than 80mm, and the length of the non-working face end of the male die is not less than 130 mm.
Further preferably, the insulating protective layer prepregs of the inner layer and the outer layer in the step (6) are glass fiber prepregs.
Further preferably, the inner-layer multilayer insulation protection layer prepreg in the step (6) comprises an inner-layer cured glass fiber prepreg shell and a soft glass fiber prepreg shell with an outer layer against the electric heating unit component; the outer multi-layer insulating protective layer comprises a soft glass fiber prepreg shell, a middle solidified glass fiber prepreg shell and an outer soft glass fiber prepreg shell, wherein the inner layer of the shell is close to the electric heating unit component; manufacturing the cured glass fiber prepreg shell: fixing the cut glass fiber prepreg cloth double-layer crossed cloth veins on a convex film of an electric heating unit mould, then putting the sealed bag into an autoclave after vacuumizing and compacting, curing and forming at the temperature of 130-. The solidified glass fiber prepreg shell prevents burrs of prepreg carbon fiber cloth in the skin from penetrating through to be connected with the electric heating unit to cause short circuit, damage to the electric heating unit and heating failure of the electric heating unit.
Further preferably, the electric heating unit assembly in the step (6) is a carbon nano electric heating unit assembly; the carbon nano electric heating unit component comprises an inner insulating protective layer, an outer insulating protective layer and five identical carbon nano tube membrane electric heating sheets which are connected in series by copper sheets, wherein a gap of one carbon nano tube membrane electric heating sheet is arranged between every two adjacent carbon nano tube membrane electric heating sheets; the five carbon nanotube film electric heating sheets except the two wiring terminals are sealed, tightly attached, clamped and fixed in the inner and outer insulating protective layers with slightly larger sizes, and then folded in half, so that the two carbon nanotube film electric heating sheets are just positioned in the gaps between the other three carbon nanotube film electric heating sheets, and the two wiring terminals are led out in the same direction up and down.
The carbon beam mold is used for manufacturing the carbon beam, the operation is convenient, the production efficiency is high, bubbles among prepreg layers can be forced to be pushed out, the foam core is not damaged, and the compactness and the strength of each layer of carbon fiber prepreg cloth are high; and the carbon beam can wrap the flat block of the metal blade handle integrally, and the upper wall and the lower wall are accurately fixed in the upper accommodating groove and the lower accommodating groove of the foam core, so that the integral strength of the blade is improved. And when each layer of skin and the electric heating unit assembly are paved in the mold cavity, the pressure-bearing strength of the foam core is high, the foam core is not easy to damage, and the process is relatively simple. The blade front edge is paved with the electric heating unit component, so that the phenomenon of icing of the wind tunnel blade front edge can be effectively prevented, the occurrence of large vibration of the blade caused by icing is avoided, the test is smoothly carried out, and the damage to equipment in the wind tunnel caused by the falling of ice blocks caused by icing is also avoided. Especially, when the electrical heating unit assembly is the carbon nanometer electrical heating unit assembly, the thickness of the carbon nanometer film electrical heating sheet assembly is only 0.01mm, the weight is light, the thermal expansion coefficient is small, the deformation after heating can be ignored, the blade structure can not be damaged after heating, and the layer can be formed along with the change of the blade airfoil shape, so that the use is very convenient.
In a word, the carbon beam is used as a main bearing part of the blade, and the carbon beam has strong compactness of a layer and high strength; the corresponding blades have high strength, and the service life of the wind tunnel blades is prolonged; and the icing phenomenon of the front edge of the wind tunnel blade does not occur under the wet and cold environment.
Drawings
FIG. 1 is a schematic view of a blade according to the present invention;
FIG. 2 is a cross-sectional view AA in FIG. 1;
FIG. 3 is a cross-sectional view BB of FIG. 2;
FIG. 4 is a schematic view of the construction of the foam core in the blade of the present invention;
FIG. 5 is a schematic view of a metal blade shank of the present invention;
FIG. 6 is a schematic view of a carbon beam in a blade according to the present invention;
FIG. 7 is a schematic structural view of the carbon beam mold of the present invention as viewed from the working face side;
FIG. 8 is a front view of the carbon beam mold of the present invention as viewed from the face side;
FIG. 9 is a top view of FIG. 8;
FIG. 10 is a left side view of FIG. 8;
FIG. 11 is a schematic view of the carbon beam mold and metal petioles of the present invention as seen from the working face side;
FIG. 12 is a schematic structural view of a carbon nanotube film electrical heater chip assembly of an electrical heating unit assembly in a blade according to the present invention;
FIG. 13 is a schematic view of the structure at the leading edge of the blade in a blade with an electrical heating unit assembly according to the present invention;
FIG. 14 is a perspective view of the electrically heated unit die of the present invention from a non-working face;
fig. 15 is a front view of the electric heating unit mold of the present invention as seen from the working plane;
FIG. 16 is a top plan view of the electrically heated unit die of the present invention as seen from the working surface;
fig. 17 is a left side view of the electric heating unit mold of the present invention as viewed from the working surface;
fig. 18 is a right side view of the electric heating unit mold of the present invention as viewed from the working surface;
fig. 19 is a cross-sectional view AA of fig. 15.
Detailed Description
The invention is further described with reference to the following figures and specific embodiments.
As shown in fig. 1 to 19, the present embodiment includes the following steps:
(1) the upper and lower molds are made according to the actual shape and size requirements of the blade as shown in fig. 1. Cutting 5-10 layers of carbon fiber prepreg (or glass fiber prepreg) required by manufacturing the skin 1, and marking, laying and positioning marks. Making foam 2 core shoulder and tip padding strips.
(2) And (3) processing the foam core 2 (foaming and molding the foam core can also be adopted) by using foam numerical control processing equipment. The shape of the foam core 2 is the same as that of the blade body of the blade, one end of the foam core, which is provided with the blade handle 3, is provided with a groove 201 for accommodating the blade handle 3, the working surface and the non-working surface of the foam core are respectively provided with an upper accommodating groove 203 and a lower accommodating groove of the upper wall 52 and the lower wall 53 of the carbon beam 5, and two flat bosses 202 protrude from the bottom surface of the groove 201. 204 is the leading edge.
(3) The metal petiole 3 is machined using a numerical control machining apparatus. One end of the metal blade handle 3 is a hollow cylinder 306 with a mounting step on the outer circle, the other end is a flat block 307 which is completely matched with the groove 201 of the foam core, and a narrow flat connecting waist 301 is arranged between the hollow cylinder 306 and the flat block 307. One end of the flat block 307 far away from the hollow cylinder 306 is provided with a central lightening hole 303 communicated with the hollow cylinder and boss accommodating grooves 302 and 304 on two sides of the lightening hole 303 and completely matched with the two bosses 202 of the foam core, and the side surface of the flat block close to the connecting waist 301 is provided with a wire routing hole 305 of the electric heating unit component 4 communicated with the central lightening hole 303.
(4) The carbon beam 5 is manufactured using a carbon beam mold.
A. The carbon beam mold comprises a base 11 and the special-shaped strip mold 6 fixed on the base 11. The special-shaped long mould 6 is integrally formed, the lower end part of the special-shaped long mould is a fixed block 14, the upper end part of the special-shaped long mould is provided with a petiole installation groove 8 which is completely matched with a flat block 307 of the metal petiole 3, and a positioning shaft 7 matched with a central lightening hole 303 of the petiole protrudes on the bottom surface of the petiole installation groove 8. The part between the fixing block 14 and the petiole mounting groove 8 is provided with a front layer laying groove 9 and a rear layer laying groove, and the parts clamped by the front layer laying groove and the rear layer laying groove are the same as the parts clamped by the upper holding groove, the lower holding groove, the upper holding groove and the lower holding groove of the foam core 2 in irregular shape and size. The centre of the upper end face of the base 11 is fixed with a clamping groove formed by the front clamping plate 10 and the rear clamping plate and matched with a fixed block 14 at the lower end of the special-shaped strip die 6, and the fixed block 10 and the clamping groove wall, namely the clamping plate 10 and the front clamping plate, are both provided with mounting holes (13 are mounting holes on the clamping plate 10), and the fixed block and the clamping groove wall are fixed together through the mounting holes. Preferably, universal wheels 12 are respectively fixed at four corners of the carbon beam mold base 11; the castor 12 is provided with locking means (or may not be provided with locking means). Hoisting holes 15 are formed in the left side face and the right side face of the upper end of the special-shaped strip die 6.
B. The petiole 3 is installed on the foam core 2, the carbon fiber prepreg cloth is cut according to the shape and the size of the expanded shape formed by the end surface where the connecting waist of the petiole flat block 307 is located, the upper wall and the lower wall of the petiole flat block 307 and the bottom surfaces of the upper accommodating groove and the lower accommodating groove of the foam core 2, connecting holes matched with the flat connecting waist 301 of the metal petiole 3 are formed in the cut carbon fiber prepreg cloth, and positioning marks are marked and laid. And determining the cutting layer number according to the thickness of the carbon fiber prepreg and the thickness requirements of the upper and lower accommodating grooves of the foam core.
C. Manufacturing a carbon beam 5; the front and rear layer laying grooves of the carbon beam mold are adhered with demolding cloth, the manufactured metal petioles 3 are inserted into the petiole mounting grooves 8 of the carbon beam mold, and the positioning shafts 7 of the carbon beam mold are inserted into the central lightening holes 303 of the metal petioles 3. Then laying the cut carbon fiber prepreg cloth according to the required laying sequence: after the connecting hole of the cut carbon fiber prepreg cloth passes through the hollow cylinder of the metal petiole 3, the connecting hole is paved on the end surface 308 where the connecting waist 301 of the petiole flat block is positioned, the front wall and the rear wall of the petiole flat block 307 and the front and rear paving grooves of the carbon beam mold by using a scraper, 15-20 layers of the carbon beam mold are paved, after the carbon beam mold is paved, the carbon beam mold is integrally vacuumized and compacted, and the manufactured carbon beam 5 and the metal petiole 3 are taken down from the mold.
The manufactured carbon beam 5 comprises a vertical connecting wall 54 at the blade shank end and upper and lower walls 52 and 53 which are integrated with the vertical connecting wall 54, the shape and the size of the end surface 308 of the vertical connecting wall 54, where the connecting waist 301 of the flat blade shank block 307 is located, are completely the same, a connecting waist accommodating hole 54 is formed in the center of the end surface, and the shape and the size of the upper and lower walls 52 and 53 are completely matched with the upper accommodating groove 203 and the lower accommodating groove of the foam core 2 respectively.
(5) Blade forming: the metal petiole 3 coated with the carbon beam 5 is inserted into the petiole-containing groove 201 of the foam core 2, and the carbon beam 5 is wrapped and installed in the upper and lower containing grooves of the metal petiole 3 and the foam core 2. Laying each layer of carbon fiber prepreg or glass fiber prepreg of the skin 1 in a lower die cavity according to a required laying sequence, then placing the metal petiole 3, the foam core 2 and the carbon beam 5 which are arranged together on the inner layer of the skin of the lower die cavity, and attaching cushion strips at the shoulder and the tip of the foam core 2. And (3) wrapping the skin 1 on the metal petiole 3, the foam core 2 and the carbon beam 5, and overlapping the lower edge of the skin 1 on the upper edge by not less than 30 mm. After the upper die and the lower die are closed, the upper die and the lower die are placed into a press to be cured and molded at the high temperature of 130-180 ℃, and the upper die and the lower die are taken down after molding is finished.
Preferably, the embodiment further comprises a step (6), in the step (5), when the remaining 1-2 layers are laid on the skin 1, the semi-finished blade is taken out from the cavity of the lower die, then the semi-finished blade is placed on the tool, the electrically heated unit component 4 is wrapped and fixed on the front edge of the blade body, then the semi-finished blade is placed in the cavity of the lower die, the last 1-2 layers of the skin 1 are laid, after the upper die and the lower die are closed, the semi-finished blade is placed in an autoclave to be cured and molded at the temperature of 130-.
The electric heating unit assembly 4 is manufactured by using an electric heating unit mold:
A. the electric heating unit mould is an integrated piece, the lower end of the electric heating unit mould is provided with a base 16, and the base 16 is upwards protruded with a convex mould 19 which has the same shape and size with the front edge of the blade body of the blade in the skin 1-2 layers. The upper end surfaces 20 of the bases on the left side and the right side of the male die 19 are planes, the perimeter of the working surface end 18 of the male die 19 is the perimeter of the electric heating unit component 4 wrapped from the boundary line of the front edge of the blade body to the working surface end, and the perimeter of the non-working surface end 22 is the perimeter of the electric heating unit component 4 wrapped from the boundary line of the front edge of the blade body to the non-working surface end. The upper end surfaces 17 and 21 of the bases at the front end and the rear end of the convex membrane 19 are curved surfaces and respectively change along with the change of the connecting curves of the two edges of the electric heating unit 4 and the front edge of the blade body. The widths of the upper end faces 20, 17 and 21 of the bases at the left side, the right side, the front end and the rear end of the convex film 19 ensure that the positions left after the laying is finished can still be fixed by the vacuum bag.
B. And manufacturing an electric heating unit assembly 4, cutting more than two layers of insulating protection layer prepregs according to the overall length requirement of the electric heating unit assembly 4, and cutting the electric heating unit. Laying a layer of insulating protection layer prepreg on a plane workbench, bonding a heating element on the insulating protection layer, adding a layer of insulating protection layer prepreg, sealing and wrapping the rest heating elements except two wiring terminals of the heating element in the insulating protection layer prepreg, and bending to lead the two wiring terminals out from the upper part and the lower part of one direction to form an electric heating unit. Then laying one or more layers of insulating protection layer prepregs on the inner layer on a male die 19 of the electric heating unit die according to insulation requirements, laying the electric discharge heating unit, and finally laying one or more layers of insulating protection layer prepregs on the outer layer; and (5) vacuumizing and compacting the sleeve sealing bag.
Preferably, the length of the working face end 18 of the male die 19 is not less than 80mm, and the length of the non-working face end 22 is not less than 130 mm.
Preferably, the insulating protective layer prepregs of the inner layer and the outer layer in the step (6) are glass fiber prepregs.
Preferably, the inner layer of multilayer insulation protection layer prepreg in step (6) comprises an inner cured fiberglass prepreg shell 47 and an outer soft fiberglass prepreg shell 46 next to the electrical heating unit assembly 4. The outer multi-layer insulating protective layer comprises an inner soft fiberglass prepreg shell 46 adjacent the electrical heating unit assembly 4, an intermediate cured fiberglass prepreg shell 47, and an outer soft fiberglass prepreg shell 46. Manufacturing the cured glass fiber prepreg shell: fixing the cut glass fiber prepreg cloth with double-layer crossed cloth veins on the convex film 19 of the electric heating unit mould, then putting the sealed bag into an autoclave after vacuumizing and compacting, curing and forming at the temperature of 130-.
Preferably, the electrical heating unit assembly 4 in step (6) is a carbon nano electrical heating unit assembly. The carbon nano electric heating unit component comprises an inner insulating protective layer, an outer insulating protective layer and five identical carbon nano tube membrane electric heating sheets 42 which are connected in series through copper sheets 45, and a gap 43 of one carbon nano tube membrane electric heating sheet is arranged between every two adjacent carbon nano tube membrane electric heating sheets 42. Five carbon nanotube film electric heating sheets 42 except the two connecting terminals 41 and 44 are tightly sealed, clamped and fixed in the inner and outer insulating protective layers with slightly larger sizes, and then folded along the bending line 46, so that the two carbon nanotube film electric heating sheets 42 are just positioned in the gap 43 between the other three carbon nanotube film electric heating sheets 42, and the two connecting terminals 41 and 44 are led out from the upper and lower parts of the petioles of the electric heating sheets 42.
There are, of course, many other embodiments of the invention and modifications and variations of this invention that will be obvious to those skilled in the art may be made without departing from the spirit and scope of the invention, but it is intended to cover all such modifications and variations as fall within the true spirit and scope of the invention.
Claims (10)
1. A preparation method of a wind tunnel blade comprises the following steps:
(1) manufacturing an upper die and a lower die according to the actual shape and size requirements of the blade; cutting 5-10 layers of carbon fiber prepreg cloth or glass fiber reinforced plastic prepreg cloth required by manufacturing the skin, and marking, laying and positioning marks; manufacturing cushion strips at the shoulder and the tip of the foam core; the method is characterized in that: it also includes the following steps:
(2) processing the foam core or the foam molding foam core by using foam numerical control processing equipment; the shape of the foam core is the same as that of the blade body of the blade, one end of the foam core, which is provided with a blade handle, is provided with a groove for accommodating the blade handle, the working surface and the non-working surface of the foam core are respectively provided with an upper accommodating groove and a lower accommodating groove of the upper wall and the lower wall of the carbon beam, and two flat bosses are raised on the bottom surface of the groove;
(3) processing the metal petiole by using numerical control processing equipment; one end of the metal blade handle is a hollow cylinder with an installation step on the excircle, the other end of the metal blade handle is a flat block which is completely matched with the groove of the foam core, and a narrow flat connection waist is arranged between the hollow cylinder and the flat block; one end of the flat block, which is far away from the hollow cylinder, is provided with a central lightening hole communicated with the hollow cylinder and boss accommodating grooves which are arranged on two sides of the lightening hole and are completely matched with two bosses of the foam core, and the side surface of the flat block, which is close to the connecting waist, is provided with a wire routing hole of an electric heating unit component communicated with the central lightening hole;
(4) manufacturing a carbon beam by using a carbon beam mold;
A. the carbon beam mold comprises a base and a special-shaped strip mold fixed on the base; the special-shaped long strip die is integrally formed, the lower end part of the special-shaped long strip die is a fixed block, the upper end part of the special-shaped long strip die is provided with a petiole installation groove which is completely matched with the flat block of the metal petiole, and a positioning shaft matched with a central lightening hole of the petiole protrudes from the bottom surface of the petiole installation groove; the part between the fixing block and the petiole mounting groove is provided with a front layer groove and a rear layer groove, and the parts clamped by the front layer groove and the rear layer groove and the front layer groove and the rear layer groove are the same as the parts clamped by the upper holding groove, the lower holding groove, the upper holding groove and the lower holding groove of the foam core in special shape and size; a clamping groove matched with the fixing block at the lower end of the special-shaped strip die is fixed at the center of the upper end face of the base, mounting holes are formed in the fixing block and the wall of the clamping groove, and the fixing block and the wall of the clamping groove are fixed together through the mounting holes;
B. installing a petiole on a foam core, cutting carbon fiber prepreg according to the shape and the size of the spread end surface where the connecting waist of the flat petiole block is located, the upper wall and the lower wall of the flat petiole block and the shape and the size of the upper accommodating groove and the lower accommodating groove of the foam core, opening a connecting hole matched with the flat connecting waist of the metal petiole on the cut carbon fiber prepreg, and marking and laying a positioning mark; determining the number of cutting layers according to the thickness of the carbon fiber prepreg and the thickness requirements of the upper and lower holding tanks of the foam core;
C. manufacturing a carbon beam; sticking demolding cloth on the front and rear layer laying grooves of the carbon beam mold, inserting the manufactured metal petiole into the petiole mounting groove of the carbon beam mold, and inserting the positioning shaft of the carbon beam mold into the central lightening hole of the metal petiole; then laying the cut carbon fiber prepreg cloth according to the required laying sequence: after a connecting hole of the cut carbon fiber prepreg cloth penetrates through a hollow cylinder of a metal petiole, paving the connecting hole on the end surface where the connecting waist of the flat petiole block is located, the front wall and the rear wall of the flat petiole block and the front and rear layer paving grooves of a carbon beam mold by using a scraper, performing vacuum compaction once when 15-20 layers are paved, and after the paving is performed, performing vacuum compaction once on the whole, taking down the prepared carbon beam and the metal petiole from the mold;
(5) blade forming: inserting the metal petiole coated with the carbon beam into a groove of the foam core for accommodating the petiole, and wrapping and installing the carbon beam in the upper and lower accommodating grooves of the metal petiole and the foam core; laying each layer of carbon fiber prepreg or glass fiber prepreg of the skin in a lower die according to a required laying sequence, then placing the metal petioles, the foam cores and the carbon beams which are arranged together on the inner layer of the skin of the cavity of the lower die, and attaching cushion strips at the shoulders and the tips of the foam cores; wrapping the skin on the metal petiole, the foam core and the carbon beam, and lapping the lower edge of the skin on the upper edge by not less than 30 mm; after the upper die and the lower die are assembled, the upper die and the lower die are placed into an autoclave to be cured and molded at the temperature of 130-180 ℃, and the upper die and the lower die are taken down after molding is finished.
2. The method for producing a wind tunnel blade according to claim 1, wherein: the method also comprises a step (6), in the step (5), when the skin is laid for 1-2 layers, the semi-finished blade is taken out from the cavity of the lower die, then the semi-finished blade is placed on a tool, the electric heating unit component is wrapped and fixed on the front edge of the blade body, then the semi-finished blade is placed in the cavity of the lower die, the last 1-2 layers of the skin are laid, after the upper die and the lower die are assembled, the semi-finished blade is placed in a hot-pressing tank to be cured and molded at the temperature of 130-;
manufacturing an electric heating unit assembly by using an electric heating unit mold:
A. the electric heating unit mould is an integrated piece, the lower end of the electric heating unit mould is a base, and the base is upwards protruded to form a convex mould which is the same as the shape and size of the front edge of the blade body of the blade in the 1-2 layers of the covering; the upper end surfaces of the bases on the left side and the right side of the male die are planes, the perimeter of the working surface end of the male die is the perimeter of the electric heating unit wrapped from the front edge boundary line of the blade body to the working surface end, and the perimeter of the non-working surface end of the male die is the perimeter of the electric heating unit wrapped from the front edge boundary line of the blade body to the non-working surface end; the upper end surfaces of the bases at the front end and the rear end of the convex membrane are curved surfaces and respectively change along with the change of the connecting curves of the two edges of the electric heating unit component and the front edge of the blade body; the widths of the upper end faces of the bases at the left side, the right side, the front end and the rear end of the convex film ensure that the positions left after the paving is finished can still be fixed by fixing the vacuum pumping bag;
B. manufacturing an electric heating unit assembly, and cutting more than two layers of insulating protection layer prepregs according to the overall length requirement of the electric heating unit assembly; laying an insulating protection layer prepreg on a plane workbench, bonding an electric heating element on the insulating protection layer, adding a layer of insulating protection layer prepreg, hermetically wrapping the rest electric heating elements except two wiring terminals of the electric heating element in the insulating protection layer prepreg, and bending to lead the two wiring terminals out from one direction to the bottom to manufacture an electric heating unit; then laying one or more layers of insulating protection layer prepregs on the inner layer on a male die of the electric heating unit die according to the insulation requirement, laying the electric discharge heating unit, and finally laying one or more layers of insulating protection layer prepregs on the outer layer; and (5) vacuumizing and compacting the sleeve sealing bag.
3. The method for producing a wind tunnel blade according to claim 2, wherein: and (3) the prepregs of the insulating protective layers of the inner layer and the outer layer in the step (6) are all glass fiber prepreg cloth.
4. The method for producing a wind tunnel blade according to claim 2, wherein: the inner-layer multilayer insulation protection layer prepreg in the step (6) comprises an inner-layer cured glass fiber prepreg shell and a soft-state glass fiber prepreg shell of which the outer layer is close to the electric heating unit component; the outer multi-layer insulating protective layer comprises a soft glass fiber prepreg shell, a middle solidified glass fiber prepreg shell and an outer soft glass fiber prepreg shell, wherein the inner layer of the shell is close to the electric heating unit component; manufacturing the cured glass fiber prepreg shell: fixing the cut double-layer crossed cloth veins of the glass fiber prepreg cloth on a convex film of an electric heating unit mould, then putting the sealed bag into an autoclave after vacuumizing and compacting, curing and forming at the temperature of 130-180 ℃, and taking down.
5. A method of producing a wind tunnel blade according to claim 2, 3 or 4, wherein: the electric heating unit assembly in the step (6) is a carbon nano electric heating unit assembly; the carbon nano electric heating unit component comprises an inner insulating protective layer, an outer insulating protective layer and five identical carbon nano tube membrane electric heating sheets which are connected in series by copper sheets, wherein a gap of one carbon nano tube membrane electric heating sheet is arranged between every two adjacent carbon nano tube membrane electric heating sheets; the five carbon nanotube film electric heating sheets except the two wiring terminals are sealed, tightly attached, clamped and fixed in the inner and outer insulating protective layers with slightly larger sizes, and then folded in half, so that the two carbon nanotube film electric heating sheets are just positioned in the gaps between the other three carbon nanotube film electric heating sheets, and the two wiring terminals are led out in the same direction up and down.
6. The method for producing a wind tunnel blade according to claim 5, wherein: the length of the working face end of the male die is not less than 80mm, and the length of the non-working face end of the male die is not less than 130 mm.
7. The method for producing a wind tunnel blade according to claim 6, wherein: in the step (4) A, universal wheels are respectively fixed at four corners of the carbon beam mold base; the universal wheel is provided with a locking device or not; hoisting holes are formed in the left side face and the right side face of the upper end of the special-shaped strip die.
8. A method of producing a wind tunnel blade according to claim 2, 3 or 4, wherein: the length of the working face end of the male die is not less than 80mm, and the length of the non-working face end of the male die is not less than 130 mm.
9. The method for producing a wind tunnel blade according to claim 8, wherein: in the step (4) A, universal wheels are respectively fixed at four corners of the carbon beam mold base; the universal wheel is provided with a locking device or not; hoisting holes are formed in the left side face and the right side face of the upper end of the special-shaped strip die.
10. The method for producing a wind tunnel blade according to claim 1, 2, 3 or 4, wherein: in the step (4) A, universal wheels are respectively fixed at four corners of the carbon beam mold base; the universal wheel is provided with a locking device or not; hoisting holes are formed in the left side face and the right side face of the upper end of the special-shaped strip die.
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| CN114193793A (en) * | 2021-12-13 | 2022-03-18 | 惠阳航空螺旋桨有限责任公司 | Blade for axial-flow compressor |
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