WO2014199065A2 - Method for manufacturing a composite part - Google Patents

Method for manufacturing a composite part Download PDF

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Publication number
WO2014199065A2
WO2014199065A2 PCT/FR2014/051387 FR2014051387W WO2014199065A2 WO 2014199065 A2 WO2014199065 A2 WO 2014199065A2 FR 2014051387 W FR2014051387 W FR 2014051387W WO 2014199065 A2 WO2014199065 A2 WO 2014199065A2
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WO
WIPO (PCT)
Prior art keywords
composite
auxiliary
main
composite part
auxiliary structure
Prior art date
Application number
PCT/FR2014/051387
Other languages
French (fr)
Inventor
Xavier Cazuc
John Moutier
Nicolas BEKAERT
Crésus DUTOT
Original Assignee
Aircelle
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Aircelle filed Critical Aircelle
Publication of WO2014199065A2 publication Critical patent/WO2014199065A2/en

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Classifications

    • 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
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • 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
    • B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement

Definitions

  • the present invention relates to a method of manufacturing a composite part.
  • a composite structure may for example be manufactured by draping a mold of a plurality of composite plies formed of unidirectional ribbons or plies pre-impregnated or not with a resin.
  • the draping operation is in a known manner typically carried out by a method of automated deposition of these composite folds, for example by means of a numerically controlled machine.
  • This polymerization step consists in cooking the fresh folds, for example in an autoclave.
  • the composite parts are reinforced by a metal or composite honeycomb structure that is positioned on a portion of the composite structure draped. This type of reinforcement typically makes it possible to ensure good resistance to the compressive forces of the composite part.
  • the honeycomb structure is not directly supported by the draped composite structure.
  • the draped composite structure receives an extra thickness constituted by a so-called “auxiliary" composite structure, of dimensions equal to those of the honeycomb structure to be supported.
  • This auxiliary composite structure typically consisting of small composite folds, is integral with the so-called “main” composite structure and supports the honeycomb structure.
  • the auxiliary composite structure also generally manufactured by the automated composite ply deposition method, defines a local reinforcement zone of the main composite structure, and typically comprises a plurality of composite plies stacked and angularly offset from one another.
  • the composite folds 5 defining a layer of an auxiliary structure deposited on the main structure 1 by the automated deposition method.
  • the composite plies 5 defining a layer of the auxiliary structure do not exactly match the desired theoretical layup zone 3.
  • the tool does not respect the desired draping area.
  • the composite part 7 comprises the main structure 1 reinforced locally by the auxiliary structure 9 obtained by a stack of composite ply layers, and supporting a honeycomb structure 1 January.
  • the composite part 7 comprises two zones having recesses 13, 15. These recesses correspond in fact to the difference between the theoretical draping surface of the desired auxiliary structure and the actual surface obtained by the automated deposition method. composite folds.
  • the positioning of the composite folds constituting the auxiliary structure 9 is achieved by means of a laser projection tool, defining precisely, on the main structure, the contour of the zone intended to receive said auxiliary composite folds.
  • the laser projection tool ensures optimal positioning of the lay-up areas of the auxiliary composite folds, and the manual draping of the auxiliary composite folds makes it possible to overcome the problems related to the bad bonding of the honeycomb structure on the damaged auxiliary composite structure.
  • the laser projection method is expensive, and the mold placement operations supporting the main composite structure under the laser projectors are complex, and of relatively long duration.
  • the present invention aims to overcome the drawbacks of the prior art, and relates for this purpose to a method of manufacturing a composite part comprising at least one main structure and at least one structure other than the solitary element of the ladite main structure and dimensions smaller than said main structure, said method being remarkable in that it comprises the following steps aimed at:
  • At least one marking tape on said main structure delimiting a draping zone of the auxiliary structure
  • the method according to the invention comprises an additional step aimed at:
  • the present invention also relates to a composite part comprising at least one main structure and at least one auxiliary structure directly integral with said main structure and of dimensions smaller than said main structure, remarkable in that it is obtained from the method according to the invention.
  • the composite folds of the auxiliary structure are small, that is to say having a length typically less than about 100 millimeters.
  • the auxiliary structure of the composite part according to the invention comprises a stack of at least two composite layers formed of a plurality of unidirectional composite plies, said layers being angularly offset relative to each other.
  • the manufactured composite part is a fixed internal structure of a nacelle thrust reverser for turbojet engine.
  • the invention relates to a turbojet engine nacelle comprising at least one thrust reverser comprising at least one fixed internal structure according to the invention.
  • FIG. 1 schematically illustrates a top view of a composite part being manufactured by a method according to the prior art
  • FIG. 2 is a schematic representation of the composite part obtained by a method according to the prior art
  • FIG. 3 is a view similar to that of FIG. 1, the composite part being now realized by the manufacturing method according to the invention
  • FIG. 4 represents the composite part of FIG. 3, the composite folds of the auxiliary structure having been deposited on the main structure;
  • the first step of the method according to the invention consists in draper su r a mold (not shown) the composite folds defining the main composite structure 1.
  • This draping method is preferably carried out by means of a numerically controlled machine providing automated draping of the folds made in a compact manner, a process which is well known in the art, which will not be discussed further in the present invention. description.
  • the method according to the invention provides for defining a draping zone 17 of the auxiliary composite structure by depositing marker ribbons 19, 21.
  • These reference marks are typically constituted by composite folds consisting of carbon fibers pre-impregnated with a resin.
  • the auxiliary structure to be produced is of rectangular shape.
  • two reference ribbons are sufficient to define the drape area 17.
  • the method according to the invention can provide for the removal of more than two fiducial ribbons as a function of the geometric shape to be produced.
  • the marker ribbons are deposited by automated draping.
  • the numerically controlled machine is programmed to deposit the ribbons 19, 21 so as to define, at least partially, the outline of the draping area 17 of the auxiliary structure, so that said ribbons delimit said drape area.
  • the composite folds of the auxiliary structure can be deposited on the main structure, in the draping zone 17, as illustrated in FIG. 4 on which a composite layer is represented. 23 formed of several unidirectional composite folds positioned side by side.
  • Each composite fold 5 is a unidirectional fold, that is to say that the fibers composing said fold are all oriented in the same direction.
  • the angular offset typically consists of positioning a first layer whose composite folds that constitute it have "0 °" fibers. Next, we position a second layer whose composites have fibers 45 ° offset from those of the first layer. This layer stacking process is iterated as many times as necessary.
  • the composite folds of the auxiliary structure are deposited manually, so as to allow positioning of the composite folds 5 strictly corresponding to the draping zone 17.
  • the method according to the invention then comprises a polymerization step, consisting in a known manner of cooking the set of fresh folds draped in an autoclave.
  • the reference ribbons 19, 21 are still present during this firing step, but it is of course quite possible to remove these reference ribbons before the polymerization step, for example by peeling.
  • honeycomb structure 1 1 is typically attached to the auxiliary structure by gluing, but it can of course be fixed by any other means known to those skilled in the art.
  • the auxiliary structure 9 of the composite part 7 obtained by means of the method according to the invention does not have any hollow, bumps, or accidents of shape, unlike that of the composite part obtained by a method according to the prior art and shown in FIG.
  • the risk of generating rough parts is considerably reduced while reducing the manufacturing time of the composite part.
  • the mechanical strength of the composite parts produced by the process according to the invention is improved compared to the prior art, in that the risks of tearing or detachment of the honeycomb structure of the auxiliary structure are limited. .
  • the method according to the invention may, preferably but not exclusively, be used to manufacture a fixed internal nacelle thrust reverser structure for a turbojet engine.
  • the mechanical strength of the composite parts requiring a structural reinforcement in compression is increased, while reducing the manufacturing times of such composite parts, compared with those obtained by methods known from the prior art.
  • the risk of tearing or detachment of the honeycomb structure of the auxiliary composite structure is reduced in that the auxiliary structure supporting the honeycomb structure no longer has any form accidents, and the manufacturing times are substantially reduced by that manual draping of the auxiliary structure no longer requires positioning on the main structure by laser projection.
  • the method according to the invention is surprising in that it is ultimately possible to increase the mechanical strength of a composite part while reducing its manufacturing costs.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)

Abstract

The present invention relates to a method for manufacturing a composite part comprising at least one main structure (1) and at least one auxiliary structure which is secured directly to said main structure and has smaller dimensions than said main structure. The method according to the invention is noteworthy in that it comprises the following steps of: -successively draping, by way of an automated draping method: o a plurality of composite plies that define the main structure (1); o at least one reference strip (19, 21) on said main structure (1), delimiting a draping zone (17) for the auxiliary structure; -manually draping, in said draping zone (17) for the auxiliary structure, a plurality of composite plies (5) that define said auxiliary structure; -polymerizing at least said main structure (1) and auxiliary structure.

Description

Procédé de fabrication d'une pièce composite  Method of manufacturing a composite part
La présente invention se rapporte à un procédé de fabrication d'une pièce composite. The present invention relates to a method of manufacturing a composite part.
Une structure composite peut par exemple être fabriquée par le drapage sur un moule d'une pluralité de plis composites formés de rubans ou plis unidirectionnels pré-imprégnés ou non d'une résine. L'opération de drapage est de façon connue typiquement réalisée par un procédé de dépose automatisée de ces plis composites, par exemple grâce à une machine à commande numérique.  A composite structure may for example be manufactured by draping a mold of a plurality of composite plies formed of unidirectional ribbons or plies pre-impregnated or not with a resin. The draping operation is in a known manner typically carried out by a method of automated deposition of these composite folds, for example by means of a numerically controlled machine.
Ensuite, les plis sont polymérisés afin de durcir la structure en frais drapée. Cette étape de polymérisation consiste à cuire les plis frais, par exemple en autoclave.  Then, the pleats are cured to harden the draped fresh structure. This polymerization step consists in cooking the fresh folds, for example in an autoclave.
Il est fréquent que les pièces composites soient renforcées par une structure alvéolaire métallique ou composite que l'on positionne sur une portion de la structure composite drapée. Ce type de renfort permet typiquement d'assurer une bonne résistance aux efforts de compression de la pièce composite.  It is common that the composite parts are reinforced by a metal or composite honeycomb structure that is positioned on a portion of the composite structure draped. This type of reinforcement typically makes it possible to ensure good resistance to the compressive forces of the composite part.
En fait, la structure alvéolaire n'est pas directement supportée par la structure composite drapée. La structure composite drapée reçoit une surépaisseur constituée par une structure composite dite « auxiliaire » , de dimensions égales à celles de la structure alvéolaire à supporter. Cette structure composite auxiliaire, typiquement constituée par des plis composites de petite taille, est solidaire de la structure composite dite « principale » et supporte la structure alvéolaire.  In fact, the honeycomb structure is not directly supported by the draped composite structure. The draped composite structure receives an extra thickness constituted by a so-called "auxiliary" composite structure, of dimensions equal to those of the honeycomb structure to be supported. This auxiliary composite structure, typically consisting of small composite folds, is integral with the so-called "main" composite structure and supports the honeycomb structure.
La structure composite auxiliaire, elle-aussi généralement fabriquée grâce au procédé de dépose automatisée des plis composites, définit une zone de renfort local de la structure composite principale, et comprend typiquement plusieurs plis composites empilés et décalés angulairement les uns par rapport aux autres.  The auxiliary composite structure, also generally manufactured by the automated composite ply deposition method, defines a local reinforcement zone of the main composite structure, and typically comprises a plurality of composite plies stacked and angularly offset from one another.
On se réfère à la figure 1 , illustrant une structure composite principale 1 sur laquelle on a représenté une zone de drapage théorique 3 de la structure auxiliaire, réalisée par un procédé selon l'art antérieur.  Referring to Figure 1, illustrating a main composite structure 1 on which there is shown a theoretical draping area 3 of the auxiliary structure, carried out by a method according to the prior art.
Sur cette figure sont représentés les plis composites 5 définissant une couche d'une structure auxiliaire, déposés sur la structure principale 1 par le procédé de dépose automatisé. Comme on peut le remarquer, les plis composites 5 définissant une couche de la structure auxiliaire ne correspondent pas exactement avec la zone de drapage théorique 3 souhaitée. In this figure are represented the composite folds 5 defining a layer of an auxiliary structure, deposited on the main structure 1 by the automated deposition method. As can be seen, the composite plies 5 defining a layer of the auxiliary structure do not exactly match the desired theoretical layup zone 3.
Cette différence provient du fait que l'outillage de dépose automatisée est généralement calibré pour fonctionner avec des plis d'une taille minimale d'une centaine de millimètres.  This difference stems from the fact that the automatic removal tooling is generally calibrated to operate with folds of a minimum size of one hundred millimeters.
Lorsque les plis sont de petite taille, c'est-à-dire de taille inférieure à une centaine de millimètres, ce qui est typiquement le cas pour une telle structure auxiliaire, l'outillage ne permet pas de respecter la zone drapage souhaitée.  When the folds are small, that is to say less than a hundred millimeters, which is typically the case for such an auxiliary structure, the tool does not respect the desired draping area.
On se réfère à présent à la figure 2, illustrant la pièce composite 7 finalement obtenue.  Referring now to Figure 2, illustrating the composite part 7 finally obtained.
La pièce composite 7 comprend la structure principale 1 renforcée localement par la structure auxiliaire 9 obtenue par un empilement de couches de plis composites, et supportant une structure alvéolaire 1 1 .  The composite part 7 comprises the main structure 1 reinforced locally by the auxiliary structure 9 obtained by a stack of composite ply layers, and supporting a honeycomb structure 1 January.
Comme on peut le remarquer, la pièce composite 7 comprend deux zones présentant des creux 13, 15. Ces creux correspondent en fait à la différence entre la surface théorique de drapage de la structure auxiliaire souhaitée et la surface réelle obtenue par le procédé de dépose automatisée des plis composites.  As can be seen, the composite part 7 comprises two zones having recesses 13, 15. These recesses correspond in fact to the difference between the theoretical draping surface of the desired auxiliary structure and the actual surface obtained by the automated deposition method. composite folds.
Ces creux constituent des accidents de forme de la pièce composite 7, et peuvent entraîner un mauvais collage, voire un arrachement de la structure alvéolaire 1 1 de la structure auxiliaire 9.  These hollows constitute accidents of shape of the composite part 7, and can lead to poor bonding or tearing of the honeycomb structure 1 1 of the auxiliary structure 9.
Pour pallier cet inconvénient, il est courant de draper les plis composites 5 de petite taille constituant la structure auxiliaire non pas par drapage automatisé, mais manuellement.  To overcome this disadvantage, it is common to drape the composite folds 5 of small size constituting the auxiliary structure not by automated draping, but manually.
Pour cela, le positionnement des plis composites 5 constituant la structure auxiliaire 9 est réalisé grâce à un outil de projection laser, définissant de manière précise, sur la structure principale, le contour de la zone destinée à recevoir lesdits plis composites auxiliaires.  For this, the positioning of the composite folds constituting the auxiliary structure 9 is achieved by means of a laser projection tool, defining precisely, on the main structure, the contour of the zone intended to receive said auxiliary composite folds.
L'outil de projection laser assure un positionnement optimal des zones de drapage des plis composites auxiliaires, et le drapage manuel des plis composites auxiliaires permet de s'affranchir des problèmes liés au mauvais collage de la structure alvéolaire sur la structure composite auxiliaire accidentée. Toutefois, le procédé de projection laser est onéreux, et les opérations de mise en place du moule supportant la structure composite principale sous les projecteurs laser sont complexes, et de durée relativement importante. The laser projection tool ensures optimal positioning of the lay-up areas of the auxiliary composite folds, and the manual draping of the auxiliary composite folds makes it possible to overcome the problems related to the bad bonding of the honeycomb structure on the damaged auxiliary composite structure. However, the laser projection method is expensive, and the mold placement operations supporting the main composite structure under the laser projectors are complex, and of relatively long duration.
La présente invention vise à résoudre les inconvénients de la technique antérieure, et se rapporte à cet effet à un procédé de fabrication d'une pièce composite comprenant au moins une structure principale et au moins u ne structure auxil iaire d irectement sol idaire de lad ite structure principale et de dimensions inférieures à ladite structure principale, ledit procédé étant remarquable en ce qu'il comprend les étapes suivantes visant à :  The present invention aims to overcome the drawbacks of the prior art, and relates for this purpose to a method of manufacturing a composite part comprising at least one main structure and at least one structure other than the solitary element of the ladite main structure and dimensions smaller than said main structure, said method being remarkable in that it comprises the following steps aimed at:
- draper successivement, par un procédé de drapage automatisé :  - draper successively, by an automated draping process:
o une pluralité de plis composites définissant la structure principale ;  a plurality of composite folds defining the main structure;
o au moins un ruban repère sur ladite structure principale délimitant une zone de drapage de la structure auxiliaire ;  at least one marking tape on said main structure delimiting a draping zone of the auxiliary structure;
- draper manuellement, dans ladite zone de drapage de la structure auxiliaire, une pluralité de plis composites définissant ladite structure auxiliaire ;  - draping manually, in said drape area of the auxiliary structure, a plurality of composite folds defining said auxiliary structure;
- polymériser au moins lesdites structures principale et auxiliaire. Ainsi, en définissant la zone de drapage de la structure auxiliaire grâce à un positionnement automatisé d 'au moins un ruban repère, on s'affra n ch it d e l ' uti l isation d e proj ecteu rs l aser. Cel a perm et très avantageusement de limiter le coût de fabrication d'une pièce composite, tout en en réduisant sensiblement son temps de fabrication. En outre, la dépose manuelle des plis composites auxiliaires permet, par rapport à un procédé de dépose automatisée des pl is composites, de limiter considérablement les risques de décollement ou d'arrachement de la structure alvéolaire de la structure composite auxiliaire.  polymerizing at least said main and auxiliary structures. Thus, by defining the drape zone of the auxiliary structure by means of an automated positioning of at least one marker tape, the use of the projectors is discussed. This allows and very advantageously to limit the cost of manufacturing a composite part, while significantly reducing its manufacturing time. In addition, the manual removal of the auxiliary composite folds makes it possible, in comparison with a method for automatically depositing composite plies, to considerably limit the risks of detachment or tearing out of the honeycomb structure of the auxiliary composite structure.
Optionnellement, le procédé selon l'invention comprend une étape supplémentaire visant à :  Optionally, the method according to the invention comprises an additional step aimed at:
- retirer les rubans repères avant l'étape de polymérisation ;  remove the reference ribbons before the polymerization step;
- fixer une structure alvéolaire sur ladite structure auxiliaire ;  - Fix a honeycomb structure on said auxiliary structure;
La présente invention se rapporte également à une pièce composite comprenant au moins une structure principale et au moins une structure auxiliaire directement solidaire de ladite structure principale et de dimensions inférieures à ladite structure principale, remarquable en ce qu'elle est obtenue à partir du procédé selon l'invention. Selon une caractéristique de la pièce composite selon l'invention, les plis composites de la structure auxiliaire sont de petite taille, c'est-à-dire présentant une longueur typiquement inférieure à environ 100 millimètres. The present invention also relates to a composite part comprising at least one main structure and at least one auxiliary structure directly integral with said main structure and of dimensions smaller than said main structure, remarkable in that it is obtained from the method according to the invention. According to a characteristic of the composite part according to the invention, the composite folds of the auxiliary structure are small, that is to say having a length typically less than about 100 millimeters.
En outre, la structure auxil iaire de la pièce composite selon l'invention comprend un empilement d'au moins deux couches composites formées d'une pluralité de plis composites unidirectionnels, lesdites couches étant décalées angulairement les unes par rapport aux autres.  In addition, the auxiliary structure of the composite part according to the invention comprises a stack of at least two composite layers formed of a plurality of unidirectional composite plies, said layers being angularly offset relative to each other.
Selon l'invention, la pièce composite fabriquée est une structure interne fixe d'un inverseur de poussée de nacelle pour turboréacteur.  According to the invention, the manufactured composite part is a fixed internal structure of a nacelle thrust reverser for turbojet engine.
Enfin, l'invention se rapporte à une nacelle pour turboréacteur comprenant au moins un inverseur de poussée comprenant au moins une structure interne fixe selon l'invention.  Finally, the invention relates to a turbojet engine nacelle comprising at least one thrust reverser comprising at least one fixed internal structure according to the invention.
D'autres caractéristiques, buts et avantages de la présente invention apparaîtront à la lecture de la description qui va suivre et à l'examen des figures ci-annexées, dans lesquelles : Other features, objects and advantages of the present invention will appear on reading the following description and on examining the appended figures, in which:
- la figure 1 illustre schématiquement en vue de dessus une pièce composite en cours de fabrication par un procédé selon l'art antérieur ;  - Figure 1 schematically illustrates a top view of a composite part being manufactured by a method according to the prior art;
- la figure 2 est une représentation schématique de la pièce composite obtenue par un procédé selon l'art antérieur ;  - Figure 2 is a schematic representation of the composite part obtained by a method according to the prior art;
- la figure 3 est une vue similaire à celle de la figure 1 , la pièce com posite étant à présent réal isée par le procédé de fabrication selon l'invention ;  FIG. 3 is a view similar to that of FIG. 1, the composite part being now realized by the manufacturing method according to the invention;
- la figure 4 représente la pièce composite de la figure 3, les plis composites de la structure auxiliaire ayant été déposés sur la structure principale ;  FIG. 4 represents the composite part of FIG. 3, the composite folds of the auxiliary structure having been deposited on the main structure;
- la figure 5 représente la pièce composite obtenue par le procédé selon l'invention.  - Figure 5 shows the composite part obtained by the method according to the invention.
Su r l 'ensem bl e des fig u res , des références identiq ues ou analogues désignent des organes ou ensembles d'organes identiques ou analogues. In addition to the figures, identical or similar references denote identical or similar organs or sets of members.
On se réfère à la figure 3 illustrant l'étape de définition de la zone de drapage de la structure auxiliaire. La première étape du procédé selon l'invention consiste à draper su r un moule (non représenté) les plis composites définissant la structure composite principale 1 . Referring to Figure 3 illustrating the step of defining the drape area of the auxiliary structure. The first step of the method according to the invention consists in draper su r a mold (not shown) the composite folds defining the main composite structure 1.
Ce procédé de drapage est de manière préférée réalisé grâce à une machine à commande numérique assurant le drapage automatisé des plis fra is com posites, procédé b ien con n u de l 'art a ntérieu r, qu e n o u s n e détaillerons pas d'avantage dans la présente description.  This draping method is preferably carried out by means of a numerically controlled machine providing automated draping of the folds made in a compact manner, a process which is well known in the art, which will not be discussed further in the present invention. description.
Lorsque l'étape de drapage de la structure principale est terminée, le procédé selon l'invention prévoit de définir une zone de drapage 17 de la structure composite auxiliaire par dépose de rubans repères 19, 21 .  When the draping step of the main structure is completed, the method according to the invention provides for defining a draping zone 17 of the auxiliary composite structure by depositing marker ribbons 19, 21.
Ces ru bans repères sont typiq uement constitués par des plis composites constitués par des fibres carbone pré-imprégnées d'une résine.  These reference marks are typically constituted by composite folds consisting of carbon fibers pre-impregnated with a resin.
A titre d'exemple non limitatif, la structure auxiliaire à réaliser est de forme rectangulaire. Ainsi, comme représenté, deux rubans repères suffisent à définir la zone de drapage 17. Bien sûr, toute autre forme géométrique de structure auxiliaire est envisageable. A cet effet, le procédé selon l'invention peut prévoir la dépose de plus de deux rubans repères en fonction de la forme géométrique à réaliser.  By way of non-limiting example, the auxiliary structure to be produced is of rectangular shape. Thus, as shown, two reference ribbons are sufficient to define the drape area 17. Of course, any other geometric form of auxiliary structure is conceivable. For this purpose, the method according to the invention can provide for the removal of more than two fiducial ribbons as a function of the geometric shape to be produced.
Les rubans repères sont déposés par drapage automatisé. Pour cela, la machine à commande numérique est programmée pour déposer les rubans 19, 21 de façon à définir, au moins partiellement, le contour de la zone de drapage 17 de la structure auxiliaire, de sorte que lesdits rubans délimitent ladite zone de drapage.  The marker ribbons are deposited by automated draping. For this, the numerically controlled machine is programmed to deposit the ribbons 19, 21 so as to define, at least partially, the outline of the draping area 17 of the auxiliary structure, so that said ribbons delimit said drape area.
Lorsque la zone de drapage 17 de la structure auxiliaire est délimitée, les plis composites de la structure auxiliaire peuvent être déposés sur la structure principale, dans la zone de drapage 1 7, comme l'illustre la figure 4 sur laquelle est représentée une couche composite 23 formée de plusieurs plis composites 5 unidirectionnels positionnés côte à côte.  When the draping zone 17 of the auxiliary structure is delimited, the composite folds of the auxiliary structure can be deposited on the main structure, in the draping zone 17, as illustrated in FIG. 4 on which a composite layer is represented. 23 formed of several unidirectional composite folds positioned side by side.
Chaque pli composite 5 est un pli unidirectionnel, c'est-à-dire que les fibres composant ledit pli sont toutes orientées dans la même direction.  Each composite fold 5 is a unidirectional fold, that is to say that the fibers composing said fold are all oriented in the same direction.
De façon connue, pour renforcer la structure composite auxiliaire, plusieurs couches composites sont empilées les unes sur les autres, et sont décalées angulairement les unes par rapport aux autres.  In known manner, to reinforce the auxiliary composite structure, several composite layers are stacked on each other, and are angularly offset relative to each other.
Le décalage angulaire consiste typiquement à positionner une première couche dont les plis composites qui la constituent présentent des fibres « à 0 ° » . Ensu ite, on positionne une deuxième couche dont les pl is composites présentent des fibres décalées de 45° par rapport à celles de la première couche. On itère ce procédé d'empilement des couches autant de fois que nécessaire. The angular offset typically consists of positioning a first layer whose composite folds that constitute it have "0 °" fibers. Next, we position a second layer whose composites have fibers 45 ° offset from those of the first layer. This layer stacking process is iterated as many times as necessary.
Selon le procédé de l'invention, les plis composites de la structure auxiliaire sont déposés manuellement, de façon à permettre un positionnement des plis composites 5 correspondant strictement à la zone de drapage 17.  According to the method of the invention, the composite folds of the auxiliary structure are deposited manually, so as to allow positioning of the composite folds 5 strictly corresponding to the draping zone 17.
Le procédé selon l'invention comprend ensuite une étape de polymérisation, consistant de manière connue à cuire l'ensemble de plis frais drapés en autoclave.  The method according to the invention then comprises a polymerization step, consisting in a known manner of cooking the set of fresh folds draped in an autoclave.
De préférence, les rubans repères 19, 21 sont encore présents lors de cette étape de cuisson, mais il est bien entendu tout à fait possible de retirer ces rubans repères avant l'étape de polymérisation, par exemple par pelage.  Preferably, the reference ribbons 19, 21 are still present during this firing step, but it is of course quite possible to remove these reference ribbons before the polymerization step, for example by peeling.
On se réfère maintenant à la figure 5, illustrant la pièce composite 7 obtenue grâce au procédé selon l'invention.  Referring now to Figure 5, illustrating the composite part 7 obtained by the method according to the invention.
Lorsque l'étape de polymérisation est terminée, on peut fixer sur la structure composite auxil iaire 9 la structure alvéolaire 1 1 , composite ou métallique, destinée à renforcer la pièce composite 7 fabriquée.  When the polymerization step is complete, it is possible to attach to the auxiliary composite structure 9 the honeycomb structure 11, composite or metallic, intended to reinforce the composite part 7 manufactured.
La structure alvéolaire 1 1 est typiquement fixée sur la structure auxiliaire par collage, mais elle peut bien sûr être fixée par tout autre moyen connu de l'homme du métier.  The honeycomb structure 1 1 is typically attached to the auxiliary structure by gluing, but it can of course be fixed by any other means known to those skilled in the art.
Comme on le remarque sur la figure 5, la structure auxiliaire 9 de la pièce composite 7 obtenue grâce au procédé selon l'invention le procédé selon l'invention ne présente aucu n creux, bosses , ou accidents de forme, contrairement à celle de la pièce composite obtenue par un procédé selon l'art antérieur et représentée sur la figure 2.  As can be seen in FIG. 5, the auxiliary structure 9 of the composite part 7 obtained by means of the method according to the invention, the method according to the invention does not have any hollow, bumps, or accidents of shape, unlike that of the composite part obtained by a method according to the prior art and shown in FIG.
A i n s i , g râ c e a u p ro c édé selon l'invention, on réduit considérablement les risques de générer des pièces accidentées tout en réduisant le temps de fabrication de la pièce composite.  In accordance with the invention, the risk of generating rough parts is considerably reduced while reducing the manufacturing time of the composite part.
En conséquence, la tenue mécanique des pièces composites fabriquées par le procédé selon l'invention est améliorée par rapport à l'art antérieur, en ce que l'on limite les risques d'arrachement ou de décollement de la structure alvéolaire de la structure auxiliaire.  As a result, the mechanical strength of the composite parts produced by the process according to the invention is improved compared to the prior art, in that the risks of tearing or detachment of the honeycomb structure of the auxiliary structure are limited. .
Le procédé selon l'invention peut, préférentiellement mais non limitativement, être utilisé afin de fabriquer une structure interne fixe d'inverseur de poussée de nacelle pour turboréacteur. Grâce au procédé selon l'invention, on augmente la résistance mécanique des pièces composites nécessitant un renfort structurel en compression, tout en réduisant les temps de fabrication de telles pièces composites, par rapport à ceux obtenus par des méthodes connues de l'art antérieur. The method according to the invention may, preferably but not exclusively, be used to manufacture a fixed internal nacelle thrust reverser structure for a turbojet engine. With the method according to the invention, the mechanical strength of the composite parts requiring a structural reinforcement in compression is increased, while reducing the manufacturing times of such composite parts, compared with those obtained by methods known from the prior art.
En effet, les risques d'arrachement ou de décollement de la structure alvéolaire de la structure composite auxiliaire sont réduits en ce que la structure auxiliaire supportant la structure alvéolaire ne présente plus d'accidents de forme, et les temps de fabrication sont sensiblement réduits en ce que le drapage manuel de la structure auxiliaire ne nécessite plus de positionnement sur la structure principale par projection laser.  Indeed, the risk of tearing or detachment of the honeycomb structure of the auxiliary composite structure is reduced in that the auxiliary structure supporting the honeycomb structure no longer has any form accidents, and the manufacturing times are substantially reduced by that manual draping of the auxiliary structure no longer requires positioning on the main structure by laser projection.
Enfin, le procédé selon l'invention est surprenant en ce que l'on parvient, in fine, à augmenter la résistance mécanique d'une pièce composite tout en réduisant ses coûts de fabrication. Finally, the method according to the invention is surprising in that it is ultimately possible to increase the mechanical strength of a composite part while reducing its manufacturing costs.

Claims

REVENDICATIONS
1 . Procédé de fabrication d'une pièce composite (7) comprenant au moins une structure principale (1 ) et au moins une structure auxil iaire (9) directement solidaire de ladite structure principale et de dimensions inférieures à lad ite structu re principale, led it procédé étant caractérisé en ce q u ' il comprend les étapes suivantes visant à : 1. A method of manufacturing a composite part (7) comprising at least one main structure (1) and at least one auxiliary structure (9) directly integral with said main structure and of smaller dimensions than the main structural unit, led it process characterized in that it comprises the following steps for:
- draper successivement, par un procédé de drapage automatisé :  - draper successively, by an automated draping process:
o une plural ité de pl is composites définissant la structure principale (1 ) ;  o a plurality of composite composites defining the main structure (1);
o au moins u n ruban repère (19, 21 ) sur ladite structure principale (1 ) délimitant une zone de drapage (17) de la structure auxiliaire (9) ;  at least one marking tape (19, 21) on said main structure (1) delimiting a drape zone (17) of the auxiliary structure (9);
- draper manuellement, dans ladite zone de drapage (17) de la structure auxil iaire, une pl ural ité de pl is composites (5) définissant ladite structure auxiliaire (9) ;  - Draper manually in said drape area (17) of the auxiliary structure, a pl ural ity of pl is composites (5) defining said auxiliary structure (9);
- polymériser au moins lesdites structures principale (1 ) et auxiliaire polymerizing at least said main (1) and auxiliary structures
(9). (9).
2. Procéd é selon l a revend ication 1 , caractérisé en ce qu'il comprend une étape supplémentaire visant à retirer lesdits rubans repères (19,2. Process according to claim 1, characterized in that it comprises an additional step for removing said reference ribbons (19,
21 ) avant l'étape de polymérisation. 21) before the polymerization step.
3. Procédé selon l'une des revendications 1 ou 2, caractérisé en ce qu'il comprend une étape supplémentaire visant à fixer une structure alvéolaire (1 1 ) sur ladite structure auxiliaire (9). 3. Method according to one of claims 1 or 2, characterized in that it comprises an additional step for fixing a honeycomb structure (1 1) on said auxiliary structure (9).
4. Pièce composite (7) com prenant a u mo in s u ne structu re principale (1 ) et au moins une structure auxiliaire (9) directement solidaire de lad ite structure principale et de d imensions inférieures à lad ite structure principale, caractérisée en ce qu'elle est obtenue à partir du procédé selon l'une quelconque des revendications 1 à 3. 4. Composite part (7) comprising at least one main structure (1) and at least one auxiliary structure (9) directly integral with said main structure and dimensions smaller than the main structure, characterized in that it is obtained from the process according to any one of claims 1 to 3.
5. Pièce composite (7) selon la revendication 4, caractérisée en ce que les plis composites (5) de la structure auxiliaire (9) sont de petite taille, c'est-à-d ire présentant une longueur typiquement inférieure à environ 1 00 millimètres. 5. Composite part (7) according to claim 4, characterized in that the composite plies (5) of the auxiliary structure (9) are of small size, that is to say having a length typically less than about 1 00 millimeters.
6. Pièce composite (7) selon l'une des revend ications 4 ou 5, caractérisée en ce que la structure auxiliaire (9) comprend un empilement d'au mo in s deux couches composites (23) formées d'u ne pl u ral ité de pl is composites (5) unidirectionnels, lesdites couches étant décalées angulairement les unes par rapport aux autres. 6. composite part (7) according to one of revendications 4 or 5, characterized in that the auxiliary structure (9) comprises a stack of at least two composite layers (23) formed u u pl A plurality of unidirectional composites (5), said layers being angularly offset from one another.
7. Pièce composite (7) selon l'une quelconque des revendications 4 à 6, caractérisée en ce qu'il s'agit d'une structure interne fixe d'un inverseur de poussée de nacelle pour turboréacteur. 7. Composite part (7) according to any one of claims 4 to 6, characterized in that it is a fixed internal structure of a nacelle thrust reverser for turbojet engine.
8. Nacelle pour turboréacteur comprenant au moins un inverseur de poussée com prenant au moins u ne structure interne fixe selon la revendication 7. 8. A turbojet engine nacelle comprising at least one thrust reverser comprising at least one fixed internal structure according to claim 7.
PCT/FR2014/051387 2013-06-11 2014-06-10 Method for manufacturing a composite part WO2014199065A2 (en)

Applications Claiming Priority (2)

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FR13/55364 2013-06-11
FR1355364A FR3006621B1 (en) 2013-06-11 2013-06-11 PROCESS FOR MANUFACTURING A COMPOSITE WORKPIECE

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FR3082934B1 (en) * 2018-06-26 2021-10-08 Safran Nacelles LASER PROJECTION DEVICE AND METHOD FOR MANUFACTURING PARTS FROM COMPOSITE MATERIAL BY DRAPING

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