JP2012229651A - Case, method of manufacturing case, and molding die unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To sufficiently enhance entire strength and rigidity of a fan case 1 by suppressing occurrence of meander of wrinkles or fibers on flanges 9, 13.SOLUTION: A case body 7 has a plurality of textile layers 19 including textile 17 comprising reinforced fibers from the inside to the inside of a front flange 9 and the inside of a rear flange 13. The case body 7 has a plurality of roving layers 27 including roving 25 comprising the reinforced fibers of ±0 to 10 degrees of an inclination angle (β) in addition to the plurality of the textile layers 19 in only the inside.

Description

  The present invention relates to a cylindrical case such as a fan case made of a composite material of a reinforcing fiber such as carbon fiber and a thermosetting resin such as an epoxy resin, a method for manufacturing the case for manufacturing the case, and the like. About.

  In recent years, with active research and development on new materials, composite materials (FRP) of reinforced fibers and thermosetting resins are attracting attention as lightweight and high-strength materials. Research and development to apply composite materials has been made (see Patent Document 1). The configuration of the fan case according to the prior art will be described as follows.

  The fan case according to the prior art includes a cylindrical case main body, and the case main body is made of a composite material of a reinforcing fiber such as carbon fiber and a thermosetting resin such as epoxy resin. In addition, an annular flange that can be fastened to a mating part in an aircraft engine is integrally formed at the end of the case body, and this flange is made of a reinforcing fiber such as carbon fiber and a thermosetting resin such as epoxy resin. Composed of composite material. And from the inside of a case main body to the inside of a flange, it has several textile layers containing the textile fabric which consists of reinforcing fibers, such as carbon fiber.

  When manufacturing a fan case according to the prior art, a cylindrical mold unit (mandrel mold) having a molding surface corresponding to the shape (final shape) of the fan case is used, and the mold unit is arranged around its axis. The fabric is wound around the molding surface of the mold unit by feeding the fabric to the mold unit side while rotating to form a molded product as an intermediate product (semi-finished product) that has the same shape as the fan case. To do. Then, the thermosetting resin impregnated in the molded body in advance is cured by heating the molded body. Thereby, the fan case which uses the composite material of a reinforced fiber and a thermosetting resin as a constituent material can be manufactured. Note that the fan case is removed from the mold unit after the fan case is manufactured.

US2009 / 0098337

  By the way, in order to sufficiently secure the torsional strength and torsional rigidity of the molded body, which is an intermediate product of the fan case, generally, reinforcing fibers having a fiber orientation angle of ± 0 to 10 degrees (fiber orientation) in the constituent elements of the fabric. It is necessary to include reinforcing fibers having an angle of ± 0 to 10 degrees. On the other hand, when reinforcing fibers having a fiber orientation angle of ± 0 to 10 degrees are included in the constituent elements of the woven fabric, the flexibility of the woven fabric is impaired, and when the molded body is molded using the molding die unit, Wrinkles and meandering of reinforcing fibers are generated at the bent portion of the portion corresponding to the flange, leading to a decrease in the strength and rigidity of the flange.

  In other words, when a cylindrical case such as a fan case made of a composite material of reinforcing fibers and thermosetting resin has a flange, it is difficult to sufficiently increase the strength and rigidity of the entire case. There is a problem that there is.

  Therefore, an object of the present invention is to provide a case with a novel configuration, a manufacturing method thereof, and the like that can solve the above-described problems.

  A first feature of the present invention is a cylindrical case having a composite material of reinforcing fibers and thermosetting resin as a constituent material, and a cylindrical case body made of a composite material of reinforcing fibers and thermosetting resin; An annular flange formed integrally with an end portion (end edge portion) of the case main body, made of a composite material of a reinforcing fiber and a thermosetting resin, and fastened to a mating part. A plurality of woven fabric layers including a non-crimp woven fabric made of reinforcing fibers from the inside of the flange to the inside of the flange, and in addition to the plurality of woven fabric layers, the plurality of woven fabric layers alternately. A plurality of roving layers including rovings (fiber bundles) made of reinforcing fibers (reinforced fibers having inclination angles of ± 0 to 10 degrees) that are laminated and have an inclination angle of ± 0 to 10 degrees with respect to the circumferential direction of the case body are provided. The gist .

  Note that the case includes not only a fan case in an aircraft engine but also various cylindrical cases made of a composite material of a reinforcing fiber and a thermosetting resin. The inclination angle with respect to the circumferential direction of the case body refers to an inclination angle on the acute side of the roving. For example, when the case body is inclined in the clockwise direction, the inclination angle is positive, and in the counterclockwise direction. If it is tilted, it becomes a negative tilt angle.

  According to a first feature, the roving made of reinforcing fibers having an inclination angle of ± 0 to 10 degrees is alternately stacked on the plurality of fabric layers in addition to the plurality of fabric layers in the case body. Since the plurality of the roving layers are included, the torsional strength and the torsional rigidity of the molded body that is an intermediate product (intermediate product) of the case can be sufficiently secured.

  In addition, the flange has a plurality of the fabric layers including a non-crimp fabric made of reinforcing fibers, and the plurality of roving layers are provided only inside the case body. Reinforcing fibers having a fiber orientation angle of ± 0 to 10 degrees are not included, and the moldability of the portion corresponding to the flange in the molded body can be enhanced.

  The fiber orientation angle refers to the inclination angle on the acute angle side of the reinforcing fiber with respect to the longitudinal direction of the fabric (in other words, the circumferential direction of the case body), for example, when the fiber is inclined clockwise. Becomes a positive fiber orientation angle, and when tilted counterclockwise, it becomes a negative fiber orientation angle.

  According to a second feature of the present invention, in the case manufacturing method for manufacturing a case comprising the first feature, an annular first end mold is attached to the end and the shape (final shape) of the case main body is set. By using a mandrel mold having a molding surface of a corresponding shape, and rotating the mandrel mold around its axis, a non-crimp fabric made of reinforcing fibers is supplied to the mandrel mold side, whereby the fabric is A fabric winding step for winding the mandrel mold from the molding surface to the outer peripheral surface of the first end mold, and a roving (fiber bundle) made of reinforcing fibers while rotating the mandrel mold around its axis. The roving is moved in the circumferential direction of the mandrel type by supplying it to the mandrel type side while moving relative to the mandrel type in the direction. A roving winding step of spirally winding only the molding surface of the mandrel type while maintaining an inclination angle of ± 0 to 10 degrees, and after the fabric winding step and the roving winding step, the fabric By repeating the winding step and the roving winding step alternately, a repeating step of forming a cylindrical molded body having a portion corresponding to the case body, and an end of the molded body after completion of the repeating step The part is raised from the outer peripheral surface of the first end mold, and the annular second end mold having a molding surface corresponding to the shape of the flange is replaced with the first end mold at the end of the mandrel mold And attaching the end portion of the molded body along the molding surface of the second end mold to form a portion corresponding to the flange on the end portion side of the molded body. Same shape as the case A flange forming step for finishing, and a heating step for curing the thermosetting resin previously impregnated in the molded body by heating the molded body after the flange molding process and the flange holding process are completed. This is the gist.

  The inclination angle with respect to the circumferential direction of the mandrel type means an inclination angle on the acute angle side of the roving. For example, when it is inclined clockwise, it becomes a positive inclination angle and counterclockwise. If it is tilted, it becomes a negative tilt angle.

  According to the second feature, the fabric winding step of winding the fabric from the molding surface of the mandrel mold to the outer peripheral surface of the first end mold, and the inclination of the roving with respect to the circumferential direction of the mandrel mold is ± 0. The cylindrical shaped body having a portion corresponding to the case main body is obtained by alternately repeating the roving winding step of spirally winding only on the molding surface of the mandrel type in a state maintained at -10 degrees. Since it is molded, the torsional strength and torsional rigidity of the molded body can be sufficiently ensured.

  Further, in the fabric winding step, the non-crimped fabric is wound around the outer peripheral surface of the first end mold, and in the roving step, the roving is spirally wound only on the molding surface of the mandrel type. Therefore, the reinforcing fiber having a fiber orientation angle of ± 0 to 10 degrees is not included inside the end portion of the molded body before the start of the flange molding process, and the portion corresponding to the flange in the molded body is not included. Ease of molding can be improved.

  In particular, in the flange forming step, by aligning an end of the molded body raised from the outer peripheral surface of the first end mold along the molding surface of the second end mold exchanged with the first end mold, Since the portion corresponding to the flange is molded, for example, compared to the case where the fabric is wound around the molding surface of an appropriate molding die, the portion corresponding to the flange in the molded body is easier to mold. Can be increased.

  According to the present invention, the torsional strength and torsional rigidity of the molded body can be sufficiently ensured while enhancing the molding ease of the portion corresponding to the flange in the molded body, which leads to a decrease in the strength of the composite material in the flange. Generation | occurrence | production of wrinkles and meandering of a fiber can be suppressed, and the intensity | strength and rigidity of the said case can fully be improved.

1A is an enlarged view showing an arrow IA in FIG. 3, and FIG. 1B is an enlarged view showing an arrow IB in FIG. FIG. 2 is a side view of the fan case according to the first embodiment of the present invention. FIG. 3 is a schematic side sectional view of the aircraft engine. FIG. 4 is a partial plan view of a non-crimp fabric, partly broken away. FIG. 5A is a cross-sectional view showing a mandrel type and a mandrel type rotation device in which a first front end type and a first rear end type are attached to both ends, and FIG. It is sectional drawing which shows the mandrel type | mold with which the end type | mold and the 2nd rear end type | mold were mounted | worn, and a mandrel type | mold rotation apparatus. FIG. 6 is a schematic perspective view showing a mandrel type rotating device, a fabric supply device, and a roving supply device used for carrying out the case manufacturing method according to the second embodiment of the present invention. FIG. 7: is a typical perspective view explaining the textile fabric winding process in the manufacturing method of the case which concerns on 2nd Embodiment of this invention. FIG. 8 is a schematic perspective view for explaining a roving winding step in the method for manufacturing a case according to the second embodiment of the present invention. FIG. 9 is a schematic plan view for explaining the inclination angle of the roving with respect to the circumferential direction of the mandrel mold when the roving is wound around the molding surface of the mandrel mold. FIG. 10A is a cross-sectional view showing a state after the end of the repetitive process in the case manufacturing method according to the second embodiment of the present invention, and FIG. It is sectional drawing explaining the flange shaping | molding process in a manufacturing method. FIG. 11A is a cross-sectional view illustrating a flange forming step in the case manufacturing method according to the second embodiment of the present invention, and FIG. 11B is a case manufacturing method according to the second embodiment of the present invention. It is sectional drawing explaining the flange formation process and flange holding process in FIG.

(First embodiment)
A first embodiment of the present invention will be described with reference to FIGS. In the drawings, “FF” indicates the forward direction, “FR” indicates the backward direction, “L” indicates the left direction, and “R” indicates the right direction.

  As shown in FIGS. 2 and 3, the fan case 1 according to the first embodiment of the present invention is used for the aircraft engine 3 and covers a plurality of fan blades 5 in the aircraft engine 3. The fan case 1 is made of a composite material of a reinforcing fiber such as carbon fiber, aramid fiber, or glass fiber and a thermosetting resin such as epoxy resin, phenol resin, or polyimide resin. The outer diameter changes along the axial direction of the case 1.

  The fan case 1 includes a cylindrical case body 7, and the case body 7 is made of a composite material of a reinforcing fiber such as carbon fiber and a thermosetting resin such as epoxy resin. An annular front flange 9 is integrally formed at the front end portion (one end portion) of the case body 7, and the front flange 9 is formed of a reinforcing fiber such as carbon fiber and a thermosetting resin such as epoxy resin. It is made of a composite material and can be fastened to an engine cowl 11 (an example of a counterpart part) in the aircraft engine 3. Further, an annular rear flange 13 is integrally formed at the rear end portion (the other end portion) of the case main body 7, and the rear flange 13 is made of a reinforcing fiber such as carbon fiber and a thermosetting resin such as epoxy resin. And can be fastened to a rear case 15 (an example of a counterpart component) in the aircraft engine 3.

  As shown in FIGS. 1A, 1B, and 4, a plurality of fabrics including a fabric 17 made of reinforcing fibers such as carbon fibers from the inside of the case body 7 to the inside of the front flange 9 and the inside of the rear flange 13. It has a layer 19. Here, the fabric 17 has a non-crimp structure composed of biaxial fiber bands 21 and 23 of reinforcing fibers such as carbon fibers, and the fiber orientation angle (α) of the biaxial fiber bands 21 and 23 is ± 20 to It is 70 degrees, preferably ± 30 to 60 degrees (± 45 degrees in the embodiment of the present invention). This is because if the absolute angle of the fiber orientation angle α of the biaxial fiber bands 21 and 23 is less than 20 degrees, the fan case 1 may be wrinkled or the meandering of the fibers may occur, whereas the biaxial fiber band When the absolute angle of the fiber orientation angle (α) of 21 and 23 exceeds 70 degrees, the torsional strength and torsional rigidity of the molded body 1F (see FIG. 10A), which is an intermediate product (semi-finished product) of the fan case 1, are obtained. This is because it becomes difficult to ensure. In addition, the site | part shown with the broken line in FIG. 4 is a stitch thread | yarn.

  As shown in FIGS. 1 (a), 1 (b), and 2, a plurality of rovings (fiber bundles) 25 made of reinforcing fibers such as carbon fibers in addition to the plurality of fabric layers 19 are provided only inside the case body 7. The roving layer 27 is provided. The plurality of roving layers 27 are alternately stacked on the plurality of fabric layers 19, and the outermost layer of the case body 7 is the roving layer 27. Here, the inclination angle (β) of the roving 25 with respect to the circumferential direction of the case body 7 is ± 0 to 10 degrees, preferably ± 2 to 10 degrees. This is because if the absolute angle of the inclination angle (β) of the roving 25 with respect to the circumferential direction of the case body 7 exceeds 10 degrees, it becomes difficult to ensure the torsional strength and torsional rigidity of the molded body 1F described later.

  An annular front reinforcing member having an L-shaped cross section (front additional pad) that reinforces the front flange 9 from the front end side (one end side) of the outer peripheral surface of the case body 7 to the outer side surface (opposite surface of the fastening surface) of the front flange 9 ) 29 is provided integrally. The front reinforcing member 29 is made of a composite material of a reinforcing fiber such as glass fiber and a thermosetting resin such as an epoxy resin, and is segmented along the circumferential direction.

  Similarly, an annular rear reinforcement having an L-shaped cross section that reinforces the rear flange 13 from the rear end portion side (the other end portion side) of the outer peripheral surface of the case body 7 to the outer surface of the rear flange 13 (the surface opposite to the fastening surface). A member (rear additional pad) 31 is provided integrally. The rear reinforcing member 31 is made of a composite material of reinforcing fibers such as glass fibers and a thermosetting resin such as epoxy resin, and is segmented along the circumferential direction.

  Then, the effect | action and effect of 1st Embodiment of this invention are demonstrated.

  In addition to the plurality of fabric layers 19, the case body 7 has a plurality of roving layers 27 including rovings 25 that are alternately stacked on the plurality of fabric layers 19 and are made of reinforcing fibers having an inclination angle of ± 0 to 10 degrees. Therefore, a reinforcing fiber having a fiber orientation angle (α) of ± 0 to 10 degrees (a reinforcing fiber having a fiber orientation angle (α) of ± 0 to 10 degrees) is used as a constituent element of the non-crimp fabric 17 (of the fabric layer 19). Even if excluded from the component), the torsional strength and torsional rigidity of the molded body 1F, which is an intermediate product of the fan case 1, can be sufficiently secured.

  The front flange 9 and the rear flange 13 have a plurality of fabric layers 19 including a non-crimp fabric 17 made of reinforcing fibers, and a plurality of roving layers 27 only inside the case body 7. Therefore, the reinforcing fibers having the fiber orientation angle (α) ± 0 to 10 degrees are not included in the front flange 9 and the rear flange 13, and the portion 9F corresponding to the front flange in the molded body 1F (FIG. 11). (B)) and the portion 13F corresponding to the rear flange (see FIG. 11B) can be easily formed.

  Therefore, according to the first embodiment of the present invention, the torsional strength and the torsional rigidity of the molded body 1F are improved while improving the molding ease of the portion 9F corresponding to the front flange and the portion 13F corresponding to the rear flange in the molded body 1F. Since the front flange 9 and the rear flange 13 can be sufficiently secured, the occurrence of wrinkles and fiber meandering that leads to a decrease in the strength of the composite material of the reinforcing fiber and the thermosetting resin can be suppressed, and the strength and rigidity of the entire fan case 1 can be reduced. It can be raised enough. In particular, a front reinforcing member 29 is integrally provided from the front end side of the outer peripheral surface of the case body 7 to the outer surface of the front flange 9, and from the rear end side of the outer peripheral surface of the case body 7 to the outer surface of the rear flange 13. Since the rear reinforcing member 31 is integrally provided, the strength and rigidity of the entire fan case 1 can be more sufficiently increased by suppressing the lowering of the strength and rigidity of the front flange 9 and the rear flange 13.

(Second Embodiment)
A second embodiment of the present invention will be described with reference to FIGS. 4 to 11 (a) and 11 (b). In the drawings, “FF” indicates the forward direction, “FR” indicates the backward direction, “L” indicates the left direction, and “R” indicates the right direction.

  First, the apparatus etc. which are directly used for implementation of the manufacturing method of the case which concerns on 2nd Embodiment of this invention are demonstrated.

  As shown in FIGS. 5A and 5B, the mold unit 33 according to the second embodiment of the present invention includes a mandrel mold 35, and the mandrel mold 35 is a non-crimp fabric on the outer peripheral side. 17, and has a molding surface 35 s having a shape corresponding to the shape (final shape) of the case body 7.

  An annular first front end mold 37 is detachably provided at the front end portion (one end portion) of the mandrel mold 35, and the first front end mold 37 is segmented along the circumferential direction. Further, the outer peripheral surface of the first front end mold 37 has an inclined portion 37d that is inclined with respect to the axis of the mandrel mold 35 (the axis of the first front end mold 37) so as to increase in diameter toward the front. Thus, the non-crimp fabric 17 can be wound.

  An annular second front end mold 39 is detachably provided at the front end of the mandrel mold 35 in exchange for the first front end mold 37. The second front end mold 39 extends along the circumferential direction. It is segmented. Further, the second front end mold 39 has a molding surface 39s having a shape corresponding to the shape (final shape) of the front flange 9 on the outer peripheral side.

  An annular first rear end mold 41 is detachably provided at the rear end (the other end) of the mandrel mold 35, and the first rear end mold 41 is segmented along the circumferential direction. Further, the outer peripheral surface of the first rear end mold 41 has an inclined portion 41d that is inclined with respect to the axis of the mandrel mold 35 (the axis of the first rear end mold 41) so as to increase the diameter in the rearward direction. Thus, the non-crimp fabric 17 can be wound.

  At the rear end of the mandrel die 35, an annular second rear end die 43 is detachably provided in exchange for the first rear end die 41. The second rear end die 43 is segmented along the circumferential direction. Has been. The second rear end mold 43 has a molding surface 43s having a shape corresponding to the shape (final shape) of the rear flange 13 on the outer peripheral side.

  As shown in FIGS. 5A, 5B, and 6, a mandrel type rotating device 45 that rotates the mandrel type 35 is disposed at an appropriate position, and a specific configuration of the mandrel type rotating device 45 is provided. Is as follows.

  That is, a pair of side plates 47 and 49 are provided at appropriate positions so as to oppose each other in the front-rear direction, and a rotary shaft 51 extending in the front-rear direction is rotatably provided between the pair of side plates 47 and 49. The rotating shaft 51 can set the mandrel die 35 integrally. The front side plate 47 is provided with a rotation motor 53 that rotates the rotation shaft 51 around its axis, and a main drive gear 55 is integrally provided on the output shaft of the rotation motor 53. A driven gear 57 that can mesh with the main driving gear 55 is integrally provided at the front end (one end) of the rotating shaft 51. Here, for example, by allowing the upper portions of the pair of side plates 47 and 49 to be opened and closed or separated in the vertical direction, or by adding another appropriate configuration to the pair of side plates 47 and 49, the rotating shaft 51 is paired. The side plates 47 and 49 can be attached and detached.

  On the right side (right side) of the mandrel type rotation device 45, a fabric supply device 59 for supplying the non-crimp fabric 17 to the mandrel type 35 side is provided. The specific configuration of the fabric supply device 59 is as follows. It becomes as follows.

  That is, a fixed frame 61 is disposed on the right side of the mandrel type rotating device 45, and a pair of bobbin support members 63 and 65 are provided on the upper side of the fixed frame 61 so as to face each other in the front-rear direction. The rear bobbin support member 65 can be adjusted in position in the front-rear direction. A bobbin 67 wound with a non-crimp fabric 17 is rotatably supported between the pair of bobbin support members 63 and 65. Here, for example, the upper portions of the pair of bobbin support members 63 and 65 can be opened and closed or separated in the vertical direction, or other appropriate configurations are added to the pair of bobbin support members 63 and 65. 67 can be attached to and detached from the pair of bobbin support members 63 and 65.

  A roving supply device 69 for supplying the roving 25 to the mandrel type 35 side is provided on the left side (left side) of the mandrel type rotation device 45. The specific configuration of the roving supply device 69 is as follows. It becomes like this.

  That is, a support frame 71 is disposed on the left side of the mandrel type rotating device 45, and a pair of guide rails 73 and 75 extending in the front-rear direction are provided on the support frame 71. Further, a supply head 77 for changing the supply position of the roving 25 is provided between the pair of guide rails 73 and 75 so as to be movable in the front-rear direction (the axial direction of the mandrel die 35). These are moved in the front-rear direction by driving a moving actuator (not shown) such as a moving motor.

  For convenience of explanation, the fabric supply device 59 and the roving supply device 69 are arranged on the opposite side to the mandrel type rotating device 45, but the positional relationship between the fabric supply device 59 and the roving supply device 69 is particularly limited. However, it can be implemented in various positional relationships.

Subsequently, the manufacturing method of the case according to the second embodiment of the present invention is a method for manufacturing the fan case 1 according to the first embodiment of the present invention, and includes a fabric winding step, a roving winding step, It includes a repetition process, a flange forming process, a flange holding process, and a heating process. And the concrete contents of each process are as follows. Fabric winding process As shown in FIG. 7, a mandrel mold 35 in which a first front end mold 37 and a first rear end mold 41 are respectively attached to both ends. , By rotating the bobbin 67 in conjunction with the rotation of the mandrel mold 35 while rotating the mandrel mold 35 integrally with the rotation shaft 51 around the axis thereof by driving the rotation motor 53, the non-crimp fabric 17 Is supplied to the mandrel mold 35 side. Accordingly, the non-crimp fabric 17 can be wound from the molding surface 35 s of the mandrel mold 35 to the outer peripheral surface of the first front end mold 37 and the outer peripheral surface of the first rear end mold 41.

  Here, the fabric 17 wound around the molding surface 35s of the mandrel mold 35 is impregnated with a thermosetting resin such as an epoxy resin, a phenol resin, or a polyimide resin in advance. In the fabric winding process, the number of wound layers of the fabric 17 may be one or more.

Roving process After the fabric winding process, as shown in FIG. 8, the mandrel mold 35 is rotated around the axis of the mandrel mold 35 integrally with the rotating shaft 51 by driving the rotating motor 53, and the feeding head is driven by driving the moving actuator. 77 is moved in the front-rear direction, and the roving 25 is supplied to the mandrel mold 35 side while moving in the front-rear direction. Thereby, the roving 25 can be spirally wound only on the molding surface 35 s of the mandrel mold 35.

  Here, as shown in FIG. 9, when the roving 25 is wound, the inclination angle (β) of the roving 25 with respect to the circumferential direction of the mandrel mold 35 is kept at ± 0 to 10 degrees, preferably ± 2 to 10 degrees. ing. This is because if the absolute angle of the inclination angle (β) of the roving 25 exceeds 10 degrees, it becomes difficult to ensure the torsional strength and torsional rigidity of the molded body 1F that is an intermediate product of the fan case 1. Further, the roving 25 wound around the molding surface 35s of the mandrel mold 35 is impregnated with a thermosetting resin such as an epoxy resin, a phenol resin, or a polyimide resin in advance. In the roving winding step, the number of winding layers of the roving 25 may be one or more.

Repeating Step After the fabric winding step and the roving winding step are completed, the fabric winding step and the roving winding step are alternately repeated a plurality of times. Thereby, as shown to Fig.10 (a), the cylindrical molded object 1F which has the part 7F corresponded to a case main body can be shape | molded.

  Here, in the repetitive process, the roving process is finally performed.

Flange forming step After the repetition step, as shown in FIG. 10B, the front end portion (one end portion) and the rear end portion (the other end portion) of the formed body 1F are connected to the outer peripheral surface of the first front end mold 37 and the first end portion. 1 Raise from the outer peripheral surface of the rear end type 41 respectively. Next, as shown in FIG. 11A, an annular second front end mold 39 having an L-shaped cross section is attached to the front end portion of the mandrel mold 35 in place of the first front end mold 37. Similarly, an annular second rear end mold 43 having an L-shaped cross section is attached to the rear end portion of the mandrel mold 35 in place of the first rear end mold 41. Then, as shown in FIG. 11 (b), the front end portion and the rear end portion of the molded body 1 </ b> F are respectively aligned with the molding surface 39 s of the second front end mold 39 and the molding surface 43 s of the second rear end mold 43. Thereby, a portion 9F corresponding to the front flange and a portion 13F corresponding to the rear flange are respectively formed on the front end portion side and the rear end portion side of the formed body 1F, so that the formed body 1F has the same shape as the shape of the fan case 1. Can be finished. The mounting of the second front end mold 39 and the second rear end mold 43 is performed in units of segments.

Flange holding process After the flange forming process, as shown in FIG. 11B, an L-shaped annular front reinforcing member 29 (an example of a front holding member) is arranged on the front end side of the outer peripheral surface of the molded body 1F. Thus, the front reinforcing member 29 and the second front end mold 39 cooperate to hold the portion 9F corresponding to the front flange in the molded body 1F. Similarly, by arranging an annular rear reinforcing member 31 (an example of a rear holding member) having an L-shaped cross section on the rear end side of the outer peripheral surface of the molded body 1F, the rear reinforcing member 31, the second rear end mold 43, With the cooperation, the portion 13F corresponding to the rear flange in the molded body 1F is held so as to be sandwiched. The front reinforcing member 29 and the rear reinforcing member 31 are arranged in units of segments.

Heating Step After the end of the flange holding step, the rotating shaft 51 is detached from the pair of side plates 47 and 49, and the mandrel mold 35 is removed from the rotating shaft 51. Next, the mandrel die 35 and the like are set at a predetermined position in a heating furnace (not shown) together with the molded body 1F. And the molded object 1F is heated to the predetermined | prescribed curing temperature of thermosetting resins, such as an epoxy resin, with the heater (illustration omitted) of a heating furnace. Thereby, the thermosetting resin previously impregnated into the molded body 1F can be cured.

  As described above, the fan case 1 including the composite material of the reinforcing fiber such as carbon fiber and the thermosetting resin such as epoxy resin can be manufactured.

  After manufacturing the fan case 1, the mandrel mold 35 and the like are taken out of the heating furnace together with the fan case 1. Then, the second front end mold 39 and the second rear end mold 43 are detached from the front end portion and the rear end portion of the mandrel mold 35, respectively, and the fan case 1 is removed from the mandrel mold 35. The separation of the second front end mold 39 and the second rear end mold 43 is performed in units of segments.

  The manufacturing method of the case according to the second embodiment of the present invention can be variously modified as follows. That is, for example, instead of impregnating a thermosetting resin such as an epoxy resin in advance with the fabric 17 wound around the molding surface 35s of the mandrel mold 35 and the roving 25 wound around the molding surface 35s of the mandrel mold 35, the flange holding step After the completion of the above, and before the start of the heating step, an impregnation step of impregnating the molded body 1F with a thermosetting resin such as an epoxy resin in a molten state may be provided. Further, the execution order of the fabric winding process and the roving process may be reversed, or the flange holding process may be executed in the middle of the flange forming process instead of being executed after the flange forming process.

  Then, the effect | action and effect of 2nd Embodiment of this invention are demonstrated.

  A fabric winding step of winding the fabric 17 from the molding surface 35s of the mandrel die 35 to the outer peripheral surface of the first front end die 37 and the outer peripheral surface of the first rear end die 41, and the inclination angle of the roving 25 with respect to the circumferential direction of the mandrel die 35 A tube having a portion 7F corresponding to the case body by alternately repeating a roving winding step of spirally winding only on the molding surface 35s of the mandrel die 35 with (β) maintained at ± 0 to 10 degrees. 1F, the reinforcing fibers having a fiber orientation angle (α) of ± 0 to 10 degrees (fiber orientation angles (α) ± 0 to 10 degrees) are excluded from the constituent elements of the fabric 17. In addition, the torsional strength and torsional rigidity of the molded body 1F can be sufficiently ensured.

  Further, in the fabric winding process, the non-crimp fabric 17 is wound around the outer peripheral surface of the first front end mold 37 and the outer periphery of the first rear end mold 41. In the roving process, the roving 25 is formed into the mandrel mold 35. Since only the surface 35s is spirally wound, the reinforcing fibers having a fiber orientation angle (α) of ± 0 to 10 degrees are not included in both ends of the formed body 1F before the start of the flange forming process. The ease of molding of the portion 9F corresponding to the front flange and the portion 13F corresponding to the rear flange in the molded body 1F can be enhanced.

  In particular, in the flange forming step, the front end portion of the molded body 1F raised from the outer peripheral surface of the first front end mold 37 and the rear end portion of the molded body 1F raised from the outer peripheral surface of the second front end mold 41 are Along with the molding surface 39s of the second front end mold 39 exchanged with the first front end mold 37 and the molding surface 43s of the second rear end mold 43 exchanged with the first rear end mold 41, the front flange of the molded body 1F is formed. Since the portion 9F corresponding to the corresponding portion 9F and the portion 13F corresponding to the rear flange are formed, for example, compared with the case where the fabric 17 is wound around the forming surface of an appropriate forming die (not shown), the formed body 1F The ease of forming the portion 9F corresponding to the front flange and the portion 13F corresponding to the rear flange can be further enhanced.

  Further, before starting the heating process, the front reinforcing member 29 and the second front end mold 39 cooperate with each other and the rear reinforcing member 31 and the second rear end mold 43 cooperate with each other to correspond to the front flange in the molded body 1F. Since the part 9F and the part 13F corresponding to the rear flange are held so as to be sandwiched, respectively, the deformation such as the collapse of the part 9F corresponding to the front flange and the part 13F corresponding to the rear flange in the molded body 1F during the heating process. Can be prevented.

  Therefore, according to the second embodiment of the present invention, in addition to the same effects as those of the first embodiment of the present invention described above, the portion 9F corresponding to the front flange and the rear flange in the molded body 1F during the heating process are provided. Therefore, it is possible to prevent deformation of the portion 13 </ b> F corresponding to the occurrence of a defective product of the fan case 1 and to improve the shape quality of the fan case 1.

  The present invention is not limited to the description of the above-described embodiment. For example, the first front end mold 37, the second front end mold 39, the first rear end mold 41, and the second rear end mold 43 are formed in a ring shape. Or the inclined surface 37d of the first front end mold 37 and the inclined surface 41d of the first rear end mold 41 are omitted, and the outer peripheral surface of the first front end mold 37 and the outer periphery of the first rear end mold 41 are omitted. It can be implemented in various modes by making other appropriate changes, such as configuring the surface to have the same diameter continuous with the molding surface 35s of the mandrel die 35. Further, the scope of rights encompassed by the present invention is not limited to these embodiments.

DESCRIPTION OF SYMBOLS 1 Fan case 1F molded object 3 Aircraft engine 5 Fan blade 7 Case main body 7F The part corresponding to the case main body in the molded object 9 Front flange 9F The part corresponding to the front flange in the molded object 13 Rear flange 13F Corresponding to the rear flange in the molded object Portion 17 Fabric 19 Fabric layer 25 Roving 27 Roving layer 29 Front reinforcing member 31 Rear reinforcing member 33 Mold unit 35 Mandrel mold 35s Mandrel mold surface 37 First front end mold 37d First front end inclined portion 39 Second Front end type 39s Second front end type molding surface 41 First rear end type 41d First rear end type inclined portion 43 Second rear end type 43s Second rear end type molding surface 45 Mandrel type rotating device 51 Rotating shaft 53 Rotating mode 59 fabric supply device 67 bobbin 69 roving supply device 77 supply head

Claims (12)

In a cylindrical case made of a composite material of reinforcing fiber and thermosetting resin,
A cylindrical case body made of a composite material of reinforcing fibers and thermosetting resin;
Formed integrally with the end of the case body, made of a composite material of reinforced fiber and thermosetting resin, and provided with an annular flange that can be fastened to a mating part;
From the inside of the case body to the inside of the flange, a plurality of fabric layers including a non-crimp fabric made of reinforcing fibers,
In addition to the plurality of fabric layers, only the inside of the case body is a roving made of reinforcing fibers alternately laminated on the plurality of fabric layers and having an inclination angle of ± 0 to 10 degrees with respect to the circumferential direction of the case body. A case having a plurality of roving layers.   An annular reinforcing member made of a composite material of reinforcing fiber and thermosetting resin and integrally reinforcing the flange is integrally provided from the outer peripheral surface of the case body to the outer surface of the flange. The case according to claim 1.   The case according to claim 1 or 2, wherein the outermost layer of the case body is the roving layer.   The case according to any one of claims 1 to 3, wherein the case is used for an aircraft engine and covers a plurality of fan blades in the aircraft engine. In the manufacturing method of the case for manufacturing the case of Claim 1,
An annular first end mold is attached to the end, and a mandrel mold having a molding surface corresponding to the shape of the case body is used, and the mandrel mold is made of reinforcing fibers while rotating around the axis. A fabric winding step of winding the fabric from the molding surface of the mandrel mold to the outer peripheral surface of the first end mold by supplying a non-crimp fabric to the mandrel mold side;
The roving is rotated by rotating the mandrel mold around its axis and supplying the roving made of reinforcing fibers to the mandrel mold side while moving the mandrel mold relative to the mandrel mold in the axial direction. A roving winding step of spirally winding only on the molding surface of the mandrel mold while maintaining an inclination angle of ± 0 to 10 degrees with respect to the circumferential direction of the mandrel mold;
After completion of the fabric winding step and the roving winding step, a cylindrical molded body having a portion corresponding to the case body is formed by alternately repeating the fabric winding step and the roving winding step. Repeating steps to
After the repetition step, the end of the molded body is lifted from the outer peripheral surface of the first end mold, and the annular second end mold having a molding surface corresponding to the shape of the flange is formed into the mandrel. The end of the molded body is replaced with the first end mold and mounted, and the end of the molded body is aligned with the molding surface of the second end mold, thereby corresponding to the flange on the end side of the molded body. A flange forming step of forming a portion to be finished and finishing the molded body in the same shape as the case;
A heating method for curing a thermosetting resin impregnated in the molded body in advance by heating the molded body after completion of the flange forming step.   By holding an annular holding member on the end side of the outer peripheral surface of the molded body after completion of the flange forming step and before the start of the heating step or during the flange forming step, the holding The case manufacturing method according to claim 5, further comprising a flange holding step of holding a portion corresponding to the flange in the molded body by sandwiching a member and the second end mold. Method.   The method for manufacturing a case according to claim 6, wherein the holding member is an annular reinforcing member made of a composite material of a reinforcing fiber and a thermosetting resin and reinforcing the flange.   The method of manufacturing a case according to any one of claims 5 to 7, wherein in the repeating step, the roving step is finally performed.   The woven fabric wound from the molding surface of the mandrel mold to the outer peripheral surface of the first end mold and the roving wound only on the molding surface of the mandrel mold are impregnated with a thermosetting resin in advance. The method for manufacturing a case according to any one of claims 5 to 8.   An impregnation step of impregnating the molded body with a molten thermosetting resin by injection after the end of the repeating step and before the start of the heating step is provided. The method for manufacturing a case according to claim 8.   The case according to any one of claims 5 to 10, wherein the case is a fan case used in an aircraft engine and covering a plurality of fan blades in the aircraft engine. Method. In the mold unit used directly for carrying out the method for producing a case according to claim 5,
A mandrel mold capable of winding a woven fabric made of reinforcing fibers and having a molding surface having a shape corresponding to the shape of the case body;
An annular first end mold that is detachably provided at an end of the mandrel mold and can wind a woven fabric made of reinforcing fibers on the outer peripheral surface;
And a second end mold provided at the end of the mandrel mold so as to be detachable in exchange for the first end mold and having a molding surface having a shape corresponding to the shape of the flange. Mold unit.

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