CN118119552A - 用于制造由复合材料制成的部件的方法 - Google Patents

用于制造由复合材料制成的部件的方法 Download PDF

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Publication number
CN118119552A
CN118119552A CN202280070025.1A CN202280070025A CN118119552A CN 118119552 A CN118119552 A CN 118119552A CN 202280070025 A CN202280070025 A CN 202280070025A CN 118119552 A CN118119552 A CN 118119552A
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CN
China
Prior art keywords
braiding
manufacturing
longitudinal axis
woven
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202280070025.1A
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English (en)
Inventor
P·J·费夫雷达西尔
多米尼克·玛丽·克里斯蒂安·库普
弗朗索瓦·查理
克里斯托夫·马赛尔·卢西恩·博得里吉昂
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Safran SA
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Safran SA
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Filing date
Publication date
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Publication of CN118119552A publication Critical patent/CN118119552A/zh
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/083Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • B29C70/207Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration arranged in parallel planes of fibres crossing at substantial angles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
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    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00Subject matter not provided for in other groups of this subclass
    • B29D99/0025Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282Selecting composite materials, e.g. blades with reinforcing filaments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03DWIND MOTORS
    • F03D1/00Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06Rotors
    • F03D1/065Rotors characterised by their construction elements
    • F03D1/0675Rotors characterised by their construction elements of the blades
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    • F05D2220/00Application
    • F05D2220/30Application in turbines
    • F05D2220/36Application in turbines specially adapted for the fan of turbofan engines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract

本发明涉及一种用于制造由复合材料制成的部件的方法,该方法包括:‑对具有纵向轴线(A)的结构(20)进行三维织造(S10),和‑围绕被织造的结构(20)以相对于纵向轴线呈至少一个预定角度来编织(S40)至少一层编织线。

Description

用于制造由复合材料制成的部件的方法
技术领域
本发明涉及一种用于制造复合材料部件的方法,该复合材料部件特别是航空或可再生能源领域的部件,例如是承受各种机械应力的叶片的翼梁。
背景技术
技术背景包括文献WO-A1-2021/123652、EP-A1-3 553 280、CN-A1-111 469 601、US-A1-2020/071863、US-A1-5,100,713和DE-A1-10 2018 212442。
这种叶片可用于涡轮机(例如风扇叶片、具有可变或固定桨距的导管式或非导管式旋转(转子)叶片),或用于风力涡轮。
参照图1,这种叶片2包括表皮4,表皮形成叶片2的与空气接触的空气动力表面。表皮4形成叶片的压力侧面和吸入侧面,压力侧表面和吸入侧表面由前缘6和后缘8连接。叶片在根部9和头部10之间沿着纵向轴线A延伸。
有利地,这些叶片由复合材料(特别是碳纤维或线)制成,以减轻这些叶片的重量。
叶片2还包括翼梁12以加强叶片并将叶片附接到发动机。翼梁12在表皮4的压力侧表面和吸入侧表面之间在叶片的大部分跨距上延伸。
这种类型的翼梁承受各种机械应力,特别是沿纵向轴线的拉伸力、沿垂直于纵向轴线的轴线的弯曲力和围绕纵向轴线的扭转力。
翼梁可以由任何类型的材料制成。然而,复合材料还具有能够根据施加到部件(在这种情况下是叶片)上的力来对线或纤维进行定向的优点。
这种类型的部件通常由单向堆叠的预浸渍线或长碳纤维制成,在压实和聚合之前,这些预浸渍的线或长碳纤维被放置在模具中,其连续的折叠方向不同。替代地,这种部件可以由二维织物的堆叠制成,使得对于相同数量的折叠,能够获得更大的厚度。
然而,随着部件厚度的增加,折叠层数也会增加。然而,两个层之间的交界部完全由树脂构成,因此是机械薄弱区域。
已知当待制造部件的厚度很大时,使用三维(3D)织造方法。通过使各层交织,3D织物能够保证厚部件的机械完整性。
这种用于对复合材料部件进行3D织造的方法包括织造被称为“原始”部件的第一部件,然后通过注射树脂并使树脂聚合,例如使用树脂转移模制(RTM)方法,来加固该第一部件。然后将得到的部件加工成所需的最终几何形状。原材料是通过对股线或经线、和股线或纬线进行织造而形成的。股线或经线在纵向方向上(在织造方向上)定向,并在竖直方向上延伸遍及多个叠加层。股线或纬线在横向方向上定向。厚度粘合或“互锁”是通过在纬股之间进行经股的布线来进行的。
然而,由于织造方法的原因,在织造平面中只能有线或纤维。这样,最终部件仅包括这两个方向上的纤维,即,彼此垂直定向的纤维。
为了使由复合材料制成的结构部件的强度达到最佳,纤维必须尽可能沿着与所施加的力相同的方向定向。这意味着经线方向(在织造方向上)完全适合于拉伸力和/或弯曲力。然而,这两个方向(经线方向和纬线方向),并不是增强部件抵抗扭转力的最佳方向。
这种强度要求纤维环绕整个部件,这在3D织造时在技术上是不可行的。
另一种已知的以特定角度铺设纤维的技术是编织。通常,被称为心轴的支撑件被放置在编织机的中心,编织机通过沿着心轴前进,以期望的定向铺设不同的纤维,以形成抵抗扭转的部件。支撑件可以是中空的,由泡沫制成,或者由使得支撑件能够在编织物被加固后被移除的材料制成。
尽管可以在编织物中添加与部件的纵向轴线呈0°的纤维,但是这种部件在拉伸和/或弯曲时的机械强度远低于由3D织造物制成的部件。因此,对于承受高的扭转应力的部件,这种技术可能是理想的,但是一旦力是多重的并且拉伸/弯曲不再可以忽略,这种技术就不再适用。
此外,这种编织技术不能生产实心部件。因此,部件体积的一部分填充了对部件强度没有贡献的材料,当整体尺寸对部件至关重要时,这是有问题的。
本发明的目的是提出一种用于生产针对耦合拉伸力、弯曲力和扭转力进行优化的部件的方案。
发明内容
为此,本发明涉及一种用于制造复合材料部件的方法,该方法包括:
-对具有纵向轴线的结构进行三维织造,和
-围绕被织造的结构以相对于纵向轴线呈至少一个预定角度来编织至少一层编织线。
本发明使得能够结合用于使复合材料纤维成形的两种方法的优点:三维织造和编织方法。3D织物是承受拉伸弯曲应力的厚部件的理想选择。编织物使得能够提供增强部件抵抗扭转的周向纤维。通过结合这两种方法,可以获得抵抗拉伸、弯曲以及扭转的部件,例如纵向翼梁。
有利地,本发明使得能够获得包括由复合材料制成的纤维或线的部件,纤维或线沿着部件的主要方向,在这种情况下沿着部件的纵向轴线,并且也围绕该部件。
有利地,编织厚度及其精确定向被定义为部件必须响应的拉伸力/弯曲力和扭转力之间的比率的函数。
优选地,织造线或纤维和/或编织线或纤维由碳或玻璃制成。
有利地,沿着纵向轴线围绕织造结构的预定编织角度介于15°至75°之间,优选地介于45°至75°之间。
有利地,该制造方法包括在编织步骤之前对织造结构进行树脂转移模制以对织造结构进行加固的步骤。
有利地,该制造方法包括在编织步骤之后的树脂转移模制步骤,以将部件形成其最终形状。
在一个实施例中,编织包括对至少两个层进行编织,使得能够获得部件的目标厚度。在这种情况下,编织层的编织线的预定角度从一个编织层到另一个编织层可以是不同的。
此外,在对层进行编织期间,预定角度可以有利地沿纵向轴线变化,从而使得能够获得预定的机械性能。优选地,沿纵向轴线的角度可以在15°至75°之间变化,甚至更优选地在45°至75°之间变化。例如,围绕一部段的预定织造角度可以大于围绕另一部段的预定织造角度,使得纤维尽可能接近部件的周向方向。调整纤维定向的优点是,部件的局部刚度能够根据其必须支撑的负载而被优化,从而使部件具有更高的质量性能。这样,编织物的不同定向意味着机械性能可以被局部优化。
在与前述实施例兼容的另一实施例中,该结构由经线和第一纬线形成,并且该结构包括由经线和不同于第一纬线的第二纬线形成的区域。有利地,第二纬线比第一纬线细,并且第二纬线的数量小于第一纬线的数量,从而限制经线的收缩,并形成从机械角度来看实际上是单向的区域,从而增加该区域中部件在经线方向上的刚度。
根据本发明的方法可以包括以下特征中的一个或多个,这些特征可以彼此独立地或彼此组合地考虑:
-沿纵向轴线的角度介于15°至75°之间,优选地介于45°至75°之间,
-沿纵向轴线的角度在15°至75°之间变化,优选地在45°至75°之间变化,
-编织在织造结构上并围绕织造结构进行,
-编织直接围绕织造结构进行,
-角度不为零,
-编织线相对于织造结构的纵向轴线倾斜。
本发明还涉及通过根据本发明的方法制造的复合材料部件。因此,这种部件包括形成部件芯部的织造纤维结构和形成部件外部轮廓并围绕织造纤维结构延伸的编织纤维表皮。
这种类型的部件具有非常好的拉伸、弯曲和扭转强度。
优选地,该部件是用于涡轮机叶片的复合材料翼梁。
附图说明
本发明的其他特征和优点将从下面的详细描述中变得明显,为了理解下面的详细描述,参照附图,在附图中:
-已经描述过的图1是本发明所涉及的涡轮机叶片的示意性侧视图;
-图2是根据本发明的用于制造复合材料部件的方法的流程图;
-图3是根据本发明的方法中的步骤通过3D织造获得的结构的示意性透视图;以及
-图4是包括不同编织部段的翼梁的示意性前视图。
具体实施方式
参照图2,用于制造复合材料部件的方法包括步骤S10:三维织造出具有被标记为A的纵向轴线的结构。在说明书的其余部分,待制造的部件是用于涡轮机叶片的翼梁,如图1所示。然而,本发明可以应用于必须承受拉伸、弯曲和扭转的任何部件,例如用于可再生能源装置的部件,如风力涡轮或航空推进装置(例如风扇叶片,无论是旋转的(转子)、导管式的(风扇)还是非导管式的(螺旋桨),并且该风扇叶片具有可变或固定的桨距)。
在该3D织造步骤中,3D织造结构20或预成型件由碳、玻璃或任何其他复合材料制成的线或纤维制成。
如图3所示,这本质上是一种传统的织造,经股、线或纤维21沿顺翼展方向延伸,纬股、线或纤维22沿基本垂直的方向围绕轮廓延伸。预成型件在工业织布机上织造。织造的方向用箭头F表示。经线的方向形成织造结构的纵向方向。
在3D织造结构中,通过使经线在纬线之间产生波纹/进行缠结,将所有的股线(例如碳股线)彼此织造,以形成将组件保持在一起的织物。
根据一种变型,该结构可以包括一个或多个从机械角度来看是准单向的区域,即,在该区域中,纬线比结构的其余部分更细且数量更少,使得经线实际上是直的,从而局部增加了该结构的经线方向上的刚度。
有利地,该方法还包括步骤S20:使用已知的树脂转移模制(RTM)方法对通过注射树脂并使树脂聚合而获得的预成型件进行加固,以获得机械强度。在该步骤结束时,获得“原始”结构。
该方法还包括步骤S30:加工“原始”结构以获得将在其上制造编织物的几何形状。
该方法还包括步骤S40:围绕织造结构以相对于纵向轴线呈至少一个预定角度来编织至少一层编织线。有利地,沿着纵向轴线围绕织造结构的预定编织角度介于15°至75°之间,优选地介于45°至75°之间。
编织是在工业编织机上使用碳线(或纤维)或玻璃线(或纤维)进行的。
然后将经加固和加工的3D织造结构放置在编织机中,以将编织物添加到该3D织造结构的外表面。这样,织造结构充当编织物的心轴。
为了获得待生产部件的目标厚度,可能需要多个层。必须将织造参数定义为所讨论的纤维的厚度和定向的函数,即,定义为部件必须响应的拉伸力/弯曲力和扭转力之间的比率的函数。
有利地,编织线相对于结构的纵向轴线的预定角度从一个编织层到另一个编织层可以是不同的。
此外,在对层进行编织期间,预定角度可以有利地沿纵向轴线变化,从而使得能够获得预定的机械性能。有利地,沿纵向轴线的角度可以在15°至75°之间变化,优选地在45°至75°之间变化。
根据依据该实施例制造并如图4所示的翼梁的示例,围绕旨在接近叶片根部9的下部段24织造的预定角度α1有利地大于围绕旨在比下部段24更接近叶片头部10的上部段26织造的预定角度α2,从而允许下部的纤维尽可能接近部件的周向方向。旨在靠近叶片根部的下部段将主要受到周向压缩。这将被该部段中编织物的周向定向部分地补偿。
通过这种方式,纤维的定向使得部件的局部刚度能够根据其必须支撑的负载而被优化,从而使部件具有更高的质量性能。
替代地,为了简化制造方法,或者当力在部件上均匀分布时,编织线或纤维的定向当然可以沿着部件的纵向轴线保持不变。
优选地,该方法继续包括步骤S50:使用树脂转移模制(RTM)方法对通过注射树脂并使树脂聚合而获得的编织物进行加固,以获得机械强度。
优选地,该方法包括进一步的步骤S60:加工被加固的部件以获得部件的最终几何形状。
本实施例所描述的方法包括两个树脂注射步骤:一个是对织造结构进行加固,另一个是对编织物进行加固。
在一种变型中,该方法包括单个树脂注射步骤,使得能够减少制造时间和成本。在这种情况下,该方法包括硬化织造结构(例如通过向该结构中添加增粘剂)以使织造结构可以被加工的步骤。

Claims (11)

1.一种用于制造复合材料部件的方法,所述方法包括:
-对具有纵向轴线(A)的结构(20)进行三维织造(S10),和
-围绕被织造的所述结构(20)以相对于所述纵向轴线呈至少一个预定角度来编织(S40)至少一层编织线。
2.根据权利要求1所述的制造方法,所述制造方法包括在编织步骤之前对被织造的所述结构(20)进行树脂转移模制(S20)。
3.根据权利要求1或2所述的制造方法,所述制造方法包括在编织步骤之后进行树脂转移模制(S50),以形成具有最终形状的部件。
4.根据权利要求1至3中任一项所述的制造方法,其中,所述编织包括编织至少两个层,并且其中,一个编织层的编织线的预定角度从一个编织层到另一个编织层是不同的。
5.根据权利要求1至4中任一项所述的制造方法,其中,沿所述纵向轴线的所述角度介于15°至75°之间,优选地介于45°至75°之间。
6.根据权利要求1至5中任一项所述的制造方法,其中,在对层进行编织期间,所述预定角度沿所述纵向轴线变化。
7.根据权利要求6所述的制造方法,其中,沿所述纵向轴线的所述角度在15°至75°之间变化,优选地在45°至75°之间变化。
8.根据权利要求6或7所述的制造方法,其中,被织造的所述结构(20)包括第一部段(26)和第二部段(24),并且其中,对于编织层,围绕所述第二部段(24)的预定织造角度(α1)大于围绕所述第一部段(26)的预定织造角度(α2)。
9.根据权利要求1至8中任一项所述的制造方法,其中,所述结构(20)由经线(21)和第一纬线形成,并且所述结构包括由经线(21)和第二纬线形成的区域,并且其中,所述第二纬线比所述第一纬线细,并且所述第二纬线的数量小于所述第一纬线的数量。
10.根据权利要求1至9中任一项所述的制造方法,其中,所述织造线和/或编织线是碳或玻璃。
11.根据权利要求1至10中任一项所述的方法制造的复合材料部件,所述部件是用于涡轮机叶片(2)的复合材料翼梁(12)。
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US11156126B2 (en) * 2018-04-13 2021-10-26 Raytheon Technologies Corporation Fan case with interleaved layers
DE102018212442A1 (de) * 2018-07-25 2020-01-30 Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Coburg Fahrzeugsitzgestell mit einem aus einem Faserverbundwerkstoff gefertigten Rohrelement
JP2020032629A (ja) * 2018-08-30 2020-03-05 マツダ株式会社 繊維強化樹脂製部材
FR3105291B1 (fr) * 2019-12-20 2023-03-10 Safran Aircraft Engines Aube de soufflante ou d’helice pour une turbomachine d’aeronef et son procede de fabrication
CN111469601B (zh) * 2020-05-19 2023-09-26 山东大学 一种三维编织热塑性复合材料汽车轮圈及其制备与应用

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