Monobloc preform and blade for turbo machine
10508559 ยท 2019-12-17
Assignee
Inventors
Cpc classification
F05D2300/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/603
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29L2031/08
PERFORMING OPERATIONS; TRANSPORTING
F01D25/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29B11/16
PERFORMING OPERATIONS; TRANSPORTING
F05D2220/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/282
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F01D9/041
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/6012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/222
PERFORMING OPERATIONS; TRANSPORTING
F05D2230/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29D99/0025
PERFORMING OPERATIONS; TRANSPORTING
F05D2300/6034
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D9/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/22
PERFORMING OPERATIONS; TRANSPORTING
F01D25/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29B11/16
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A fiber preform for a turbine engine blade or vane obtained by single-piece three-dimensional weaving. The preform includes a first longitudinal segment suitable for forming a root; a second longitudinal segment extending the first longitudinal segment and suitable for forming an airfoil portion; and a first transverse segment extending transversely from the junction between the first and second longitudinal segments and suitable for forming a first platform.
Claims
1. A fiber preform for a turbine engine blade or vane, the preform obtained by single-piece three-dimensional weaving, comprising: a first longitudinal segment suitable for forming a root; a second longitudinal segment extending the first longitudinal segment and suitable for forming an airfoil portion; a first transverse segment extending transversely from a junction between the first and second longitudinal segments and suitable for forming a first platform; and a second transverse segment extending transversely from the junction between the first and second longitudinal segments extending the first transverse segment and going away therefrom, suitable for forming a second platform; wherein the first transverse segment is formed by at least a portion of a free tail, said free tail and said second longitudinal segment being woven jointly in non-interlinked manner, said non-interlinking beginning at the junction between the first and second longitudinal segments; and wherein the second transverse segment and said first longitudinal segment are woven jointly in non-interlinked manner, said non-interlinking terminating at the junction between the first and second longitudinal segments.
2. The fiber preform according to claim 1, wherein a number of layers of yarns, and thus the thickness, of the second longitudinal segment varies.
3. A blade or vane for a turbine engine, the blade or vane comprising: a root; an airfoil portion; and a platform extending transversely from the airfoil at a junction between the root and the airfoil portion; said blade or vane being made as a single piece of composite material by means of the fiber preform according to claim 1, said preform being shaped in a mold and embedded in a matrix.
4. An intermediate casing for the turbine engine, the casing comprising a plurality of vanes according to claim 3 arranged angularly between an inner hub and an outer shroud.
5. The turbine engine, comprising at least one intermediate casing according to claim 4.
6. A turbine engine fan, comprising a plurality of blades according to claim 3.
7. A turbine engine, comprising at least one fan according to claim 6.
8. The turbine engine, comprising at least one blade or vane according to claim 3.
9. The blade or vane according to claim 3, wherein said matrix comprises an organic material.
10. The fiber preform according to claim 1, wherein the free tail and the second longitudinal segment are woven jointly in non-interlinked manner with a first non-interlinked plane therebetween, and wherein the second transverse segment and the first longitudinal segment are woven jointly in non-interlinked manner with a second non-interlinked plane therebetween, the second non-interlinked plane is being closer to a free end of the first longitudinal segment than the first non-interlinked plane in a longitudinal direction of the fiber preform.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are diagrammatic and seek above all to illustrate the principles of the invention.
(2) In the drawings, from one figure to another, elements (or portions of an element) that are identical are identified by the same reference signs. In addition, elements (or portions of an element) forming parts of different embodiments but having functions that are analogous are identified in the figures by numerical references that are incremented by 100, 200, etc.
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DETAILED DESCRIPTION OF EMBODIMENTS
(14) In order to make the invention more concrete, embodiments are described in detail below with reference to the accompanying drawings. It should be recalled that the invention is not limited to these embodiments.
(15)
(16) In operation, the inner casing 9 splits the stream of air accelerated by the fan 2 both into a primary stream that takes the primary passage I and feeds the compressors 3, 4, the combustion chamber 5, and the turbines 6, 7, and also into a secondary stream that takes the secondary or bypass passage II from which it is ejected out of the turbojet, thereby delivering the major part of its thrust.
(17)
(18) The structural arms 13 are hollow and serve to pass services between the core of the jet enclosed in the inner casing 9 and the periphery of the jet 1. Such services include in particular hydraulic pipework, pneumatic pipes, electric cables, and indeed mechanical power transmission shafts. These structural arms are preferably situated at 6 o'clock and at 12 o'clock relative to the axis A of the turbojet 1, i.e. in the vertical plane where most of the mechanical loads exerted by the weight of the turbojet 1 accumulate.
(19)
(20) At its bottom end, the vane root 21 has bottom fastener flanges 33 and 34 extending substantially orthogonally to the vane root 21 and provided with holes 39 enabling the vane 20 to be fastened to the inner hub 11 of the intermediate casing 10.
(21) At its top end, the vane head 23 has top fastener flanges 37 and 38 extending substantially orthogonally to the vane head 23 and provided with holes 39 enabling the vane 20 to be fastened to the outer shroud 12 of the intermediate casing 10.
(22) The vane 20 also has pressure side and suction bottom platforms 31 and 32 extending substantially orthogonally to the airfoil portion 22, on either side thereof, at the boundary between the vane root 21 and the airfoil portion 22. These bottom platforms 31 and 32 serve to mask the fastener elements, in particular screws or bolts, used for fastening the bottom flanges 33, 34, and thus the vane 20, thereby reconstituting an inner wall for the passage II that is smooth and aerodynamic.
(23) Likewise, the vane 20 has pressure side and suction side top platforms 35 and 36 extending substantially orthogonally to the airfoil portion 22, on either side thereof, at the boundary between the vane head 23 and the airfoil portion 22. These top platforms 35 and 36 serve to mask fastener elements, in particular screws or bolts, serving to fasten the top flanges 37 and 38, and thus the vane 20, thereby reconstituting an outer wall for the passage II that is smooth and aerodynamic.
(24) In this embodiment, the vane 20 has four platforms 31, 32, 35, and 36, and four fastener flanges 33, 34, 37, and 38; nevertheless, in other examples, certain platforms and/or certain flanges could be absent in order to comply with certain specific local features of the intermediate casing 10 or in order to facilitate certain aspects of assembly and of maintenance.
(25)
(26) In this embodiment, the preform 40 is 3D woven out of carbon fibers using a 3D interlock weave. Only the surfaces of the preform 40 are two-dimensionally (2D) woven using a satin type weave.
(27) At the upstream end, weaving begins with a first non-interlinked zone D1 in which third and fourth transverse segments 53 and 54 are woven simultaneously and in non-interlinked manner on opposite sides of a non-interlinked plane 61. It should be understood that the terms transverse and longitudinal are used herein as a function of the final position of the segment in question, the transverse segment necessarily being woven longitudinally prior to being folded transversely.
(28) Downstream from the first non-interlinked zone D1, there begins a first interlinked zone L1 in which the two above strips 53 and 54 are united as a first longitudinal segment 41 that forms the root 21 of the vane 20.
(29) Weaving methods that enable such non-interlinking to be performed are nowadays well known in the field of 3D weaving. By way of illustration,
(30) Downstream from this first interlink zone L1, there begins a second non-interlinked zone D2 in which a first free tail 50a, a second longitudinal segment 42, and a second free tail 50b are woven simultaneously in non-interlinked manner being separated by respective non-interlinking planes 62 and 63.
(31) In addition, within this second non-interlinked zone D2, layer exits are formed progressively along the weaving T between the second longitudinal segment 42 and each of the free tails 50a and 50b. These layers are subsequently progressively reincorporated before the downstream end of the second longitudinal segment 42.
(32) Weaving methods that enable such layer exits to be performed are nowadays well known in the field of 3D weaving. Specifically, and as can be seen in
(33) It should be observed on this topic that these layer exits are formed in this embodiment inside the preform 40 while weaving is taking place: the floated warp yarns c are thus enclosed, i.e. hidden, between the second longitudinal segment 42 on one side and the free tail 50a or 50b on the other side.
(34) Downstream from this second non-interlinked zone D2, the three above-mentioned strips 50a, 42, and 50b are reunited within a second interlinked zone L2 so as to form a third longitudinal segment 43 that is to form the head 23 of the vane 20.
(35) Finally, downstream from this second interlinked zone L2, there begins a third non-interlinked zone L3 in which seventh and eighth transverse segments are woven simultaneously in non-interlinked manner so as to present a non-interlinked plane 64.
(36) Once weaving has been terminated, the free tails 50a and 50b are cut away so as to form respectively first and fifth transverse tails 51 and 55, and second and sixth transverse tails 52 and 56. These four transverse tails 51, 55, 52, and 56 are then folded outwards as represented by the arrows so as to occupy their final transverse positions: they are used for forming respectively the pressure side and suction side bottom platforms 31 and 32, and the pressure side and suction side top platforms 35 and 36.
(37) Once the free tails 50a and 50b have been cut away, the floated warp yarns c lying at the surface of the second longitudinal segment 42 become accessible can be sheared.
(38) Finally, the third, fourth, seventh, and eighth transverse segments 53, 54, 57, and 58 are folded outwards as represented by the arrows so as to occupy their final transverse positions: they are used respectively for forming the bottom flanges 33 and 34 and the top flanges 37 and 38. Such a final configuration for the preform 40 is shown in
(39) The preform 40 may be moistened in order to make it more flexible and make it easier to frame the fibers. The preform is then inserted into a forming mold of inside space that matches the desired configuration for the preform 40.
(40) The preform 40 is then dried so as to become stiff, thereby locking the configuration imposed during shaping. The preform 40 is finally placed in an injection mold having the dimensions desired for the final vane 20, and a matrix is injected therein, in this embodiment an epoxy resin. By way of example, such injection may be performed by the resin transfer molding (RTM) technique. At the end of this step, a composite material vane 20 is obtained that is made up of a woven preform 40 of carbon fibers embedded in an epoxy matrix. Machining stages may optionally be used to finish off the technique and finalize the vane 20.
(41)
(42) The weaving of this preform 140 is to a large extent analogous to that of the first embodiment and is therefore not described in full once more.
(43) Thus, going from upstream to downstream in the weaving direction T, the weaving begins with a first non-interlinked zone D1, a first interlinked zone L1, and a second non-interlinked zone D2 analogous to those of the first embodiment. In contrast, the second non-interlinked zone D2 is extended by a third non-interlinked zone D3 in which the non-interlinked weaving of the free tails 150a and 150b is continued while a third longitudinal segment 143 extends the second longitudinal passage 142. Consequently, the third longitudinal segment 143 is naturally not as thick as in the first embodiment. It is possible to compensate this effect by using thickness-transition techniques that are well known in the field of 3D weaving.
(44) Finally, downstream from this third non-interlinked zone D3, a fourth non-interlinked zone D4 begins in which the non-interlinked weaving of the free tails 150a and 150b is continued while the strip derived from the third longitudinal segment 143 is split in a manner analogous to that of the first embodiment so as to form the seventh and eighth transverse segments 157 and 158.
(45) The shaping of this second preform embodiment 140 and the method of forming the final vane are likewise analogous to those of the first embodiment. The final configuration of the preform 140 is shown in
(46)
(47) At the upstream end, weaving begins with a first non-interlinked zone D1 in which a first free tail 251a of the first transverse segment 251, the third transverse segment 253, the fourth transverse segment 254, and a first free tail 252a of the second transverse segment 252 are all woven together in non-interlinked manner with respective non-interlinking planes 265, 261, and 266.
(48) Downstream from the first non-interlinked zone D1, there begins a second non-interlinked zone D2 in which the non-interlinked weaving of the first free tails 251a, 252a of the first and second transverse segments 251 and 252 continues, while the strips derived from the third and fourth transverse segments 253 and 254 are united in a first longitudinal segment 241 that is to form the root 21 of the vane 20.
(49) Downstream from this second non-interlinking zone D2, a first layer crossing zone C1 forms an interface with a third non-interlinked zone D3 in which a first free tail 250a, a second longitudinal segment 222, and a second free tail 250b are woven simultaneously in non-interlinked manner together with corresponding non-interlinking planes 262 and 263.
(50) At the first layer crossing zone C1, layers are crossed in such a manner that the layers of yarns from the first free tails 251a and 252a of the first and second transverse segments 251 and 252 extend towards the second longitudinal segment 242, while the layers of yarns making up the free tails 250a and 250b are derived from the first longitudinal segment 241.
(51) Weaving methods enabling layers to be crossed in this way are nowadays well known in the field of 3D weaving. By way of illustration,
(52) In the preceding example, a plurality of yarns t1 and t2 of each layer are involved in the layer crossing; however, in other examples as the one of
(53) Returning to
(54) Downstream from this third non-interlinked zone D3, a second layer crossing zone C2 forms an interface with a fourth non-interlinked zone D4 in which a second free tail 255b of the fifth transverse segment 255, the third longitudinal segment 243, and a second free tail 256b of the sixth transverse segment 256 are woven simultaneously in non-interlinked manner, with respective non-interlinking planes 267, 264, and 268.
(55) In the second layer crossing zone C2, the layers cross so that the layers of yarns from the free tails 250a and 250b are extended towards the third longitudinal segment 243 while the layers of yarns making up the second free tails 255b, 256b of the first and second transverse segments 255, 256 come from the second longitudinal segment 242.
(56) Finally, downstream from the fourth non-interlinked zone D4, there begins a fifth non-interlinked zone D5 in which the non-interlinked weaving of the second free tails 255b, 256b of the first and second transverse segments 255, 256 continues while the strip coming from the third longitudinal segment 243 splits in a manner analogous to the first embodiment in order to form the seventh and eighth transverse segments 257 and 258.
(57) Once the weaving has terminated, the free tails 250a and 250b are cut off so as to form respectively the second free tail 251b of the first transverse segment 251 and the first free tail 255a of the fifth transverse segment 255, and also the second free tail 252b of the second transverse segment 252 and the first free tail 256a of the sixth transverse passage 256.
(58) The first and second free tails of each of the transverse segments 251, 252, 255, and 256 are then folded towards one another as shown by the arrows so as to take up their final transverse positions. Adhesive or stitching may be provided between each of the first and second free tails. The transverse segments 251, 252, 255, and 256 respectively form the pressure side and suction bottom platforms 31 and 32 and the pressure side and suction side top platforms 35 and 36 of the vane 20.
(59) Once the free tails 250a and 250b have been cut away, the float yarns c that exist at the surface of the second longitudinal segment 242 become available and can be sheared.
(60) Finally, the third, fourth, seventh, and eighth transverse segments 253, 254, 257, and 258 are folded outwards as shown by the arrows so as to occupy their final transverse positions: they form respectively the bottom flanges 33 and 34 and the top flanges 37 and 38.
(61) Such a final configuration for the preform 240 is shown in
(62)
(63) The weaving of this preform 340 is largely analogous to that of the first embodiment and it is therefore not described again in full. The main difference lies in the use of non-interlinking in a relay configuration making it possible to devote only N layers of weaving to the platforms, whereas 2N layers are needed in the above embodiments.
(64) Thus, from upstream to downstream in the weaving direction T, the weaving begins with a first non-interlinked zone D1 in which the first transverse segment 351 and the first longitudinal segment 341 are woven jointly in non-interlinked manner with a non-interlinked plane 365 between them. During weaving, the first transverse segment 351 thus extends along a first side of the first longitudinal segment 341, the right-hand side in the figure.
(65) Downstream from the first non-interlinked zone D1, there begins a second non-interlinked zone D2 in which a free tail 350 and a second longitudinal segment 342 are woven jointly in non-interlinked manner with a non-interlinked plane 363 between them. In this second non-interlinked zone D2, the free tail 350 thus extends along the second side of the second longitudinal segment 342, i.e. the side opposite from the first transverse segment 351, on the left in the figure. Thus, the layers of the first transverse segment 351 are extended in the second longitudinal segment 342, while the layers of the free tail 350 are taken from the first longitudinal segment 341.
(66) Once weaving has been completed, the second transverse segment 352 is obtained by cutting the free tail 350 in a manner analogous to the above embodiments, in which the second transverse segment 352 and the first longitudinal segment 341 are woven jointly in non-interlinked manner with the non-interlinked plane 365 between them, and the non-interlinked plane 365 is closer to a free end of the first longitudinal segment 341 than the non-interlinked plane 363 in a longitudinal direction of the preform. Under such circumstances, the first transverse segment 351 and the second transverse segment 352 are folded outwards along the arrows in
(67) Other aspects of the shaping of this fourth embodiment of a preform 340 and the method of forming the final blade are likewise analogous to the shaping and the forming described above. The final configuration of the preform 340 is shown in
(68) Various layer transitions may be provided at the interface between the non-interlinked zones D1 and D2. In a first configuration shown in
(69) It may be observed at this point that the first longitudinal segment 341 may be given considerable thickness close to its bottom end and it may then be made thinner going towards the second longitudinal segment 342, in particular by making use of layer exits. This enables the blade root that is to be made using this first longitudinal segment 341 to be given a dovetail shape enabling it to be mounted in the slots of a fan disk, while also ensuring that the airfoil that is derived from the second longitudinal segment 342 is suitably thin.
(70)
(71) A specific advantage of this fourth embodiment is to reduce the number of layers devoted to weaving the platforms. If each platform possesses N layers, only one N-layer thickness is needed in addition to the layers of the longitudinal segments for the purpose of weaving both platforms, whereas two times N layers are needed in the first three embodiments, i.e. N layers on each of the two sides.
(72) A first advantage that stems directly from this reduction in the number of layers is the possibility of using a loom in a configuration that is simpler, or of making blades or vanes that are thicker or that are more complex.
(73) In addition, the thickness transition at the interface between the root and the airfoil is smaller, and that is favorable.
(74) Finally, this weaving technique gives rise to less scrap, thereby naturally reducing production costs: in this fourth embodiment, only one free tail needs to be cut, unlike two free tails in the other embodiments.
(75) The embodiments described above in the present description are given by way of non-limiting illustration, and in the light of this description a person skilled in the art can easily modify these embodiments or can envisage others, while remaining within the scope of the invention.
(76) Furthermore, the various characteristics of these embodiments may be used on their own or in combination. When they are combined, these characteristics may be combined as described above, or otherwise, the invention not being limited to the specific combinations described in the present specification. In particular, unless specified to the contrary, any characteristic described with reference to any one embodiment may be applied in analogous manner to any other embodiment.