RU2679956C1 - Aviation engine impeller and method for manufacture thereof from composite material - Google Patents

Abstract

FIELD: turbine construction.SUBSTANCE: invention relates to the field of turbine construction. Impeller of the aviation gas turbine engine contains blades, connected to the support ring, the front and rear flanges. Blade root is additionally clamped by the inter-blade fastening, integrally made with the support ring, by the front and rear flanges. At the entrance edge, the metal lining is clamped by the blade root, the front flange and the inter-blade fastener, which are tightly in contact with the metal latch stopper. In the manufacture of the specified impeller carry out cutting of the layers of material of the blades and single blanks for the support ring, front and rear flanges; in the latter, an incision is made from the point where the back edge of the blade touches the diameter to the outer circumference. Cutting for the blades is carried out with ensuring the release of material, intended for interscapular attachment, outside the shank contour. Blades are pressed together with a metal lining on the entrance edge. Put the blanks into the mold separator for the design of the front flange and the aerodynamic profile of the support ring. Install the blades in the cavity of the separator, impregnated with a binder and put the material beyond the contour of the shank, while the composite material is in tight contact with the stopper of the metal lining. Elastic punch is installed in the mold, and layers of material between the shoulder blade and the rear flange are laid thereon. Install the pressure punch and apply pressure to the elastic punch.EFFECT: group of inventions allows to increase the strength and rigidity of the impeller while reducing the specific gravity.2 cl, 12 dwg

Description

The invention relates to the field of turbine construction, more specifically to methods for manufacturing the impeller of a gas turbine engine from composite material.

A known method of manufacturing a composite blade of a gas turbine engine and a blade obtained using this method (patent RU No. 2413590, publ. 03/10/2011), according to which, by three-dimensional weaving of threads, a blank containing marking threads located at least on surface of the workpiece. Next, the workpiece is cut, leaving a number of marking threads located along the control side of the workpiece untouched, and pre-deformed, compacted and hardened. A mold is prepared for forming under pressure, in which a metal protective element protecting the leading edge, the hardened workpiece is placed and a binder containing thermosetting resin is injected into it. The same patent protects the design of the blade, containing the pen, the input edge of which is edged with a metal protective element, the leg (shank) and the transition zone connecting the pen and the leg. The blade is made from a woven blank.

The manufacturing method and design of the blades protected by this patent can be used for blades having a sufficient thickness of the input edges, which will provide the shear strength necessary to hold the metal protective element from foreign objects during engine operation. Given the tendency to reduce the thickness of the pen and the edges of the blades, this leads to the fact that a small number of layers of composite material are placed in the edge and adjacent to the area of the pen, which will not provide the strength necessary to hold the metal plate protecting the entrance edge from impact by external objects.

Protected by patent (RU No. 2502601, published December 27, 2013), a method for producing a compressor impeller from a composite material containing impellers, a support ring, front and rear flanges, including cutting layers of composite material to obtain a workpiece designed to form the front and rear flanges and parts of the support ring with an aerodynamic profile. The cutting of the layers of the composite material for the blades is carried out with the provision for going beyond the contour of the blades from the side of the main section by an amount exceeding the arc length of the support ring between adjacent blades. Then, the blades are pressed, and an outline of the support ring is obtained from the side of the root section, and part of the composite material layer remains in its original state. Next, workpieces intended for forming the front and rear flanges and parts of the support ring are placed in the mold with the arrangement of parts of the said workpiece in the cavity of the mold separator, where the front flange and the aerodynamic profile of the support ring are formed. Then, the blades are laid in the slots of the separator, providing the nominal location of the blades on the support ring, the layers of material extending beyond the contour of the blades are impregnated and laid, with the preliminary formation of the support ring. An elastic punch is installed in the mold, which forms the inner surfaces of the front and rear flanges and the support ring, layers of material for the rear flange are laid on it. Next, set the compression mold punch, fasten it to the separator, create pressure on the elastic punch, completing the formation of a monolithic impeller of the compressor.

This method is applicable for wheels with small blades. For impellers of the first stages of a compressor or fan, this method is not applicable, because the place of attachment of the blades to the support ring when the engine is operating is subjected to large forces that cannot be compensated by this design; moreover, it is difficult to reliably fix the protective metal plate on the input edge of the blade.

The creation of a highly loaded impeller from a composite material of increased strength and rigidity with a significant reduction in specific gravity, while the input edge of the blade is protected by a metal plate from impacts by foreign objects, including birds, is solved by the invention (RU No. 2617752, published on 04.26.2017), working the wheel of which includes blades, one-piece made with a support ring having an aerodynamic profile, the front and rear flanges assembled in a monolithic unit. To increase the reliability of attachment, the blades are clamped by an interscapular fastener made in the form of a surface bounded by the shanks of the blades on the support ring, the front and rear flanges, and are connected in one piece with the latter, and the metal plate is clamped by the shank, front flange and the interscapular mount (prototype).

The same invention proposed a method of manufacturing the above impeller, comprising cutting layers of composite material to obtain a workpiece designed to form the front and rear flanges and part of the support ring with an aerodynamic profile. Layering of the layers of composite material for the blades is carried out to ensure that the material leaves the contour of the shank of the blade from the side adjacent to the front flange, in the form of a surface bounded by shanks on the support ring, front and rear flanges, and from the side adjacent to the rear flange, in shape surfaces on the rear flange between the tails. Material that extends beyond the contour of the blade root is necessary as an interscapular attachment for a pinched blade root and a metal plate protecting the input edge of the blade feather from impacts by foreign objects. The pressing of the blades is carried out together with a metal plate on the input edge, while maintaining the material that extends beyond the shank contour in the initial state, and impregnating it with a binder before laying it in the separator. First of all, the blanks are laid in the mold separator and the front flange and the aerodynamic profile of the support ring are preliminarily formed. Then the material extending beyond the contour of the shank is impregnated with a binder and the blades are laid in the separator slot, which ensures the nominal location of the blades on the support ring, and the blade is mounted on the front flange and the support ring in advance, while the metal plate is pinched by the blade shaft, front flange and interscapular mount. An elastic punch is installed in the mold, designed to form the inner surfaces of the front and rear flanges and the support ring, on which the layers of interscapular fastening are laid, on top of the material for the rear flange. Next, set the pressure punch, fasten it with a separator, give pressure to the elastic punch, which ensures the formation of a monolithic impeller.

It should be noted that to increase the operational reliability of the impeller, an additional reinforcement of the shank with interscapular fastening is required, and the metal plate is equipped with a stopper. The rear impeller flange is obtained by layer-by-layer laying on the elastic punch of the workpiece sectors designed to form the front and rear flanges and part of the support ring with an aerodynamic profile, the above sectors are joined together. This rear flange assembly technology cannot provide equal strength with the front flange.

This invention solves the problem of creating an impeller from a composite material of increased strength and rigidity by enhancing the attachment of the shank and the metal plate and bringing the strength of the rear flange comparable in strength to the front flange.

This goal is achieved by the fact that when cutting composite material for blade blanks, part of the material outside the contour in the shape of the shank and the front and rear flanges bounded by the shanks of the blades, in addition to this, in the shape of the shank and the shape of the surface of the back flange bounded by the shanks tail from the side adjacent to the front flange, and from the side adjacent to the rear flange, in the form of a surface on the rear flange between the shanks. Part of the metal plate extends beyond the shank in the form of a stopper. When cutting a single blank of the support ring, the front and rear flanges, to form the latter, a cut is used from the point of interaction with the trailing edge of the blade pen along the diameter of the rear flange of the impeller. In the assembly mold, the rear flange is formed from overlapping sectors, thereby ensuring high strength of the rear flange.

In FIG. 1 and 2 - General view of the impeller.

In FIG. 3 - cutting a layer of composite material to form the front and rear flanges and the support ring.

In FIG. 4 - cutting a layer of material of the scapula.

In FIG. 5 is a cross section of a metal plate and an input edge.

In FIG. 6 - fastening in the wheel of the blade with a metal plate.

In FIG. 7 - the mold for the manufacture of the blades.

In FIG. 8 is a sectional view of a mold with a blade.

In FIG. 9, FIG. 10, FIG. 11 - a mold for assembling and pressing the impeller,

In FIG. 12 is a diagram of a stacking in a mold of layers of a composite material of a rear flange.

The impeller (Fig. 1, Fig. 2) includes blades 1 (aerodynamic profile not shown conventionally), support ring 2, front 3 and rear 4 flanges. The support ring 2 is formed from part 5 with an aerodynamic profile and the interscapular fastening of the support ring 6. From the workpiece (Fig. 3), part 5 with the aerodynamic profile of the support ring, front 3 and rear 4 flanges (Fig. 1, Fig. 2, Fig. 3). Strong fastening of the shank 9 of the blade in the impeller is achieved by the interscapular mount, including the interscapular mount of the support ring 6 and the interscapular mounts of the front 7 and rear 8, flanges, as well as the interscapular mount 29 in the shape of the shank (Fig. 1, Fig. 2, Fig. 3 , Fig. 4). The input edge 10 of the blade 1 is edged with a metal plate 11 (Fig. 1, Fig. 5), which is pinched inside the wheel by the front flange 3, the shank 9, the support ring 2 and the interscapular mountings of the front flange 7 and the shank 29 (Fig. 1, Fig. 6 ) To increase the reliability of fastening the metal plate on its base, a stopper 30 (Fig. 1, Fig, 2, Fig. 10) is made in the form of a transverse plate that is tightly in contact with the composite material of the tail 9, interscapular fastenings of the front flange 7 and the shank 29.

A method of manufacturing the impeller consists in cutting various sizes of layers of the material of the blade 1 (Fig. 4), while the layers are cut taking into account that part of the material (Fig. 1, Fig. 2) in the form of internal surfaces on part 5 with the aerodynamic profile of the support ring , on the front 3 and rear 4 flanges bounded by the shank 9 of the blades 1, extends beyond the contour from the longitudinal axis of the shank: interscapular mount 6 of the support ring, interscapular mount of the front 7 and rear 8 flanges, as well as the shape of the shank of the blade 29 (Fig. 4 )

Layers of material are also cut (Fig. 3) to form the front 3 and rear 4 flanges and part 5 with the aerodynamic profile of the support ring 2 (Fig. 1, Fig. 2). On the material of the rear flange, a cut 24 is made from the point of interaction with the trailing edge 25 of the blade pen along the diameter of the rear flange of the impeller (Fig. 3). The number of sectors 26 corresponds to the number of impeller blades. The number of layers, their sizes are calculated for each specific wheel, taking into account the configuration and the required strength. Next, each layer (Fig. 4), from which the blade 1 with the shank 9 is formed, is impregnated with a binder, then the layers together with the metal plate 11 are laid in the die 12 (Fig. 7, Fig. 8) of the mold, the punch 13 is installed and carried out pressing in accordance with the technological regime for the applied composite material. The material of the interscapular fastenings of the support ring 6, front 7 and rear 8 of the flanges and the shank 29 remains in its original state. The manufactured blade 1 at the input edge 10 and the shank 9 has a protective metal plate 11, which protects the input edge when the impeller is operated from impacts by foreign objects (Fig. 5), while the plate at the end has a stopper in the form of a transverse plate 30 (Fig. 1 , Fig. 2, Fig. 10), which is in close contact with the shank 9 of the blade 1, interscapular mounts 7 of the front flange and the shank 29.

Then the layers are impregnated with a binder (Fig. 3) and laid out on the mold, while the composite material of the front flange 3 is laid in the cavity 16 of the separator 15 (Fig. 9), where the front flange 3 is formed (Fig. 1, Fig. 2, Fig. 9, Fig. 11), and the formation of part 5 with the aerodynamic profile of the support ring 2 is made in the cavity 17 of the separator 15 (Fig. 9). When laying blanks of composite material in the mold, the slots 18 (Fig. 3) are combined with the slots 19 of the separator 15 (Fig. 9, Fig. 10).

Next, in the slot 19 of the separator 15 (Fig. 10) and in the cut 18 of the cutting (Fig. 3), the blades 1 are inserted together with the metal plate 11, which is fixed on the input edge 10 and the shank 9 (Fig. 5, Fig. 6), until stop in the housing 20 of the mold (Fig. 9, Fig. 10). Stack the material of the interscapular fastening 6, 7, 29 (Fig. 4, Fig. 9), having preliminarily impregnated with a binder, in the cavities 16 and 17 of the separator 15, respectively, pre-forming the interscapular fastening of the front flange 7, the support ring 6 and the shank 29. Then, the mold is installed elastic punch 21 (Fig. 9, Fig. 10, Fig. 11), for example, of rubber, polyurethane, etc. The material of the interscapular fastening of the rear flange 8 (Fig. 4, Fig. 9, Fig. 11) impregnated with a binder is laid on it, then the material of the rear flange 4 is laid, while the area of all sectors 26 is several times larger than the area of the rear flange 5. This creates the possibility of sector 26 when forming the rear flange 5 to overlap (Fig. 12), which will certainly increase the strength of the rear flange. As an example (Fig. 12), a scheme of laying sectors 26 is shown when their area is three times larger than the area of the rear flange 4. Next, a pressure punch 22 is installed (Fig. 11), which gives the shape and dimensions of the rear flange 22, and fasten it with a separator 15, for example, bolts (not shown) (Fig. 11). The elastic punch 21 is supplied with pressure, for example, by a cone 23 (Fig. 9, Fig. 10, Fig. 11), under the action of which the elastic punch 21 creates pressure on the composite material, designed to form the support ring 2 containing part 5 with an aerodynamic profile and interscapular mount 6 (Fig. 1, Fig. 9, Fig. 10, Fig. 11), the front flange 3 with the interscapular mount 7 of the rear flange 4 with the interscapular mount 8 and the interscapular attachment of the shank 29. Thus, the elastic punch creates pressure on parts from composite mate iala, combining them into a single unit. Curing is carried out according to the mode corresponding to the material used for the impeller.

After disassembling the mold, a monolithic impeller will be obtained (Fig. 1, Fig. 2), containing a support ring 2, front 3 and rear 4 flanges, working blades 1 with a metal plate 11 at the input edge 10. The shank 9 and the metal plate 11 are firmly pinched on the support ring 2, between the front 3 and rear 4 flanges, as well as the interscapular fasteners of the shank 29, front 7 and rear 8 flanges (Fig. 1, Fig. 6), in addition, an increased stopping power in the impeller of the metal plate creates a stopper 30 which is in close contact with the composite shank 9, interscapular fastenings of the front flange 7 and shank 29.

This invention solves the problem of creating a highly loaded impeller of the fan and compressor of the aircraft engine from a composite material of increased strength and rigidity with a significant reduction in specific gravity, while the input edge is reliably protected by a metal plate from impacts of foreign objects, including birds.

Claims (2)

1. The impeller of an aircraft engine made of composite material, including blades, one-piece made with a support ring having an aerodynamic profile, front and rear flanges and assembled in a monolithic node, while the blades, the inlet edge of which is edged with a metal plate, are inseparably connected to the front and the rear flanges and pinched by the interscapular mount, made in the form of a surface bounded by the shanks of the blades on the support ring, the front and rear flanges, and connected in one piece with the latter, and the metal plate is pinched by the shank, front flange and interscapular mount, characterized in that the shanks are reinforced with interscapular mounts in the shape of the shank surface, and the rear flange is equipped with an additional interscapular mount made in the shape of the surface of the rear flange between the shanks, while the metal plate is provided a stopper in the form of a transverse plate, which is tightly in contact with the composite material of the shank, interscapular fastenings of the front flange and shank. 2. A method of manufacturing an impeller of an aircraft engine from a composite material, comprising cutting layers of composite material for the workpiece, designed to form the front and rear flanges and part of the support ring with an aerodynamic profile, cutting layers of composite material for the blades is carried out with the material outside the contour of the shank vanes from the side adjacent to the front flange, in the form of a surface limited by shanks on the support ring, front and rear flanges, and from the side adjacent to the rear flange, according to the shape of the surface of the rear flange between the shanks, designed to pinch the shank as an interscapular fastening, the pressing of the blades is carried out together with a metal plate on the input edge, while maintaining material that extends beyond the contour of the shank, the initial state, and impregnated with its binder before laying in the separator, laying in the mold a workpiece designed to form the front and rear flanges and part of the support ring, with By burning parts of the aforementioned workpiece in the cavity of the mold separator, designed to form the front flange of the aerodynamic profile of the support ring, the subsequent laying of the blades in the slot of the separator, providing the nominal location of the blades on the support ring, then the preliminary formation of the interscapular mount on the front flange and the support ring this metal pad is pinched by the shank of the blade, the front flange and the interscapular mount, the installation in the mold of an elastic PU nson intended for the formation of the inner surfaces of the front and rear flanges and the support ring, on which the layers of material of the interscapular fastening and the rear flange are laid, the compression mold punch is installed, fastened with a separator and the formation of a monolithic impeller by pressing by applying pressure to an elastic punch, characterized the fact that the cutting of the layers of composite material for the blades is carried out with the exit of the material outside the contour of the shank of the blade from the side, adjacent to the front flange, in addition to the shape of the shank and the shape of the surface on the rear flange between the shanks, the cutting of the layers of composite material intended to form the front and rear flanges and part of the support ring with an aerodynamic profile is carried out with cutting material from the point of contact with the trailing edge blades along the diameter, with the formation of sectors that fit into the lap mold, increasing the strength of the rear flange, and the intersection is firmly laid to the stopper of the metal plate full-time fixing the front flange and the shank.

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