阅读说明：本技术 风机叶片的一体式制造方法及风机叶片 (Integrated manufacturing method of fan blade and fan blade ) 是由 景伟 刘渊 陈武超 杜言锋 谢旻 魏涛 邓俊杰 许航锋 张萌思 郑力双 刘逸斐 于 2018-05-31 设计创作，主要内容包括：本发明公开了风机叶片的一体式制造方法及风机叶片。该方法包括：形成预设形状的泡沫芯模及叶根连接孔；在泡沫芯模的外表面和叶根连接孔内铺设界面增强层材料；根据铺层方案在界面增强层材料的外表面铺设壳体预浸料,形成叶片预成型体；将叶片预成型体放入模具中并对模具进行封装；将封装后的模具放入热压罐中进行加热加压固化；以及脱模,以得到具有夹层结构的风机叶片。该风机叶片的一体式制造方法避免了现有技术中将壳体分为上下两个部分成型,然后再连接在一起的成型方法,无需二次加工和胶接,不仅尽量解决了机加工对复合材料结构的损伤以及复合材料胶接质量不易控制的问题,而且风机叶片的整体性能也较好。(the invention discloses an integrated manufacturing method of a fan blade and the fan blade. The method comprises the following steps: forming a foam core mold with a preset shape and a blade root connecting hole; paving an interface reinforcing layer material on the outer surface of the foam core mold and in the blade root connecting hole; laying shell prepreg on the outer surface of the interface reinforcing layer material according to a laying scheme to form a blade preformed body; putting the blade preformed body into a mold and packaging the mold; putting the packaged die into an autoclave for heating, pressurizing and curing; and demolding to obtain the fan blade with the sandwich structure. The integrated manufacturing method of the fan blade avoids the forming method that the shell is divided into an upper part and a lower part for forming and then connected together in the prior art, does not need secondary processing and gluing, not only solves the problems that the composite material structure is damaged by machining and the gluing quality of the composite material is not easy to control, but also has better overall performance.)

1. A method for integrally manufacturing a fan blade comprises the following steps:

Forming a foam core mold with a preset shape and a blade root connecting hole;

Paving an interface reinforcing layer material on the outer surface of the foam core mold and in the blade root connecting hole;

Laying shell prepreg on the outer surface of the interface reinforcing layer material according to a layering scheme to form a blade preformed body;

Placing the blade pre-forming body into a mold and encapsulating the mold;

putting the packaged die into an autoclave for heating, pressurizing and curing; and demolding to obtain the fan blade with the sandwich structure.

2. The integrated manufacturing method of a blower blade according to claim 1, wherein the step of forming the foam core mold and the blade root connection hole in a predetermined shape comprises:

Generating a layering scheme according to the stress condition of the fan blade in the working state;

Generating a three-dimensional graph of the foam core mold according to the shape of the fan blade, the layering scheme and the preset interference magnitude;

And processing the foam core mould with the preset shape according to the three-dimensional graph of the foam core mould.

3. The integrated fan blade manufacturing method according to claim 1, wherein after the step of laying the interfacial reinforcement layer material on the outer surface of the foam core mold and in the blade root connection hole, vacuum compaction is performed at room temperature for 20 to 30 minutes.

4. the integrated manufacturing method of a fan blade according to claim 1, wherein the step of laying a shell prepreg on the outer surface of the interface reinforcing layer material comprises:

After each 2 layers of shell prepreg was laid, the blade section width was measured and vacuum-compacted at room temperature for 20 to 30 minutes.

5. the integrated fan blade manufacturing method according to claim 1, wherein the step of placing the blade preform into a mold and encapsulating the mold comprises:

and (3) loading the blade preformed body into a mould and packaging the mould by using an isolating film, an air-permeable felt and a vacuum bag in sequence.

6. A fan blade, comprising:

The shell is integrally formed by curing composite materials;

The shell is arranged to cover the foam core die;

an interface enhancing layer sandwiched between the shell and the foam core;

And the blade root bushing is positioned in the blade root connecting hole, and the blade root connecting hole is arranged at the root of the blade along the direction vertical to the length direction of the blade.

7. the fan blade of claim 6 wherein the composite material comprises a glass fiber prepreg and/or a carbon fiber prepreg.

8. the fan blade of claim 7 wherein the shell is integrally cured from glass fiber prepreg and/or carbon fiber prepreg laid on the foam core mold.

9. The fan blade of claim 6 wherein said root bushing is bonded to said root attachment hole through said interface reinforcement layer.

Technical Field

the invention relates to the field of fan blades, in particular to an integrated manufacturing method of a fan blade and the fan blade.

background

the fan blade is a main component of the marine fan, and the accurate aerodynamic shape and the higher mechanical property of the fan blade are the keys for ensuring the working efficiency of the fan.

with the increasing maturity of composite material application technology, glass fiber reinforced plastic composite materials and carbon fiber composite materials are gradually applied to the manufacturing of fan blades. The composite material is adopted to manufacture the blades, so that various fan blades with complex shapes can be formed, and the pneumatic efficiency of the blades is improved; the composite material blade has the characteristics of light weight, high strength, corrosion resistance, good fatigue performance, shock absorption, noise reduction, easiness in installation, no maintenance and the like. These characteristics allow the useful life of the composite fan blade to be greatly increased.

Disclosure of Invention

an object of the present application is to provide an integrated manufacturing method of a fan blade and a fan blade, which can eliminate or solve the above-mentioned problems of the prior art.

the invention provides an integrated manufacturing method of a fan blade, which comprises the following steps:

forming a foam core mold with a preset shape and a blade root connecting hole;

Paving an interface reinforcing layer material on the outer surface of the foam core mold and in the blade root connecting hole;

Laying shell prepreg on the outer surface of the interface reinforcing layer material according to a layering scheme to form a blade preformed body;

placing the blade pre-forming body into a mold and encapsulating the mold;

Putting the packaged die into an autoclave for heating, pressurizing and curing; and

And (5) demolding to obtain the fan blade with the sandwich structure.

In an alternative embodiment, the step of forming the foam core mold and the blade root connection hole in a predetermined shape includes:

Generating a layering scheme according to the stress condition of the fan blade in the working state;

Generating a three-dimensional graph of the foam core mold according to the shape of the fan blade, the layering scheme and the preset interference magnitude;

and processing the foam core mould with the preset shape according to the three-dimensional graph of the foam core mould.

in an alternative embodiment, the step of laying the interfacial reinforcement material between the outer surface of the foam core and the root connection hole is followed by vacuum compaction at room temperature for 20 to 30 minutes.

in an alternative embodiment, the step of laying up the shell prepreg on the outer surface of the interfacial reinforcement material comprises:

After each 2 layers of shell prepreg was laid, the blade section width was measured and vacuum-compacted at room temperature for 20 to 30 minutes.

In an alternative embodiment, the step of placing the blade preform into a mold and encapsulating the mold comprises:

and (3) loading the blade preformed body into a mould and packaging the mould by using an isolating film, an air-permeable felt and a vacuum bag in sequence.

The present invention also provides a fan blade comprising:

the shell is integrally formed by curing composite materials;

the shell is arranged to cover the foam core die;

An interface enhancing layer sandwiched between the shell and the foam core;

and the blade root bushing is positioned in the blade root connecting hole, and the blade root connecting hole is arranged at the root of the blade along the direction vertical to the length direction of the blade.

in an alternative embodiment, the composite material comprises glass fibre prepregs and/or carbon fibre prepregs.

in an alternative embodiment, the shell is integrally cured and molded by glass fiber prepreg and/or carbon fiber prepreg laid on the foam core mold.

In an alternative embodiment, the root bushing is bonded to the root attachment hole through the interface reinforcement layer.

By means of the optimized design of the layering scheme of the fan blade and the interference fit of the mold, the integrated manufacturing method of the fan blade can avoid the situation that the shell is divided into an upper part and a lower part to be molded and then connected together in the prior art. Meanwhile, the overall co-curing molding of the blades with complex shapes can be realized by laying the layer design on the internal structure of the blades and the shell, and the composite material blade product (the complex structural characteristics of the root of the fan blade are formed together with the curing process of the fan blade) can be obtained after curing without secondary processing and bonding, so that the problems that the composite material structure is damaged by machining and the bonding quality of the composite material is not easy to control are solved, and the overall performance of the fan blade is better.

drawings

the following drawings of the invention are included to provide a further understanding of the invention. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:

FIG. 1 is a schematic cross-sectional view of a fan blade provided by an embodiment of the present invention;

FIG. 2 is a schematic front perspective view of a fan blade provided by an embodiment of the present invention;

FIG. 3 is a side perspective view of a fan blade provided by an embodiment of the present invention;

FIG. 4 is a schematic illustration of a fan blade according to an embodiment of the present invention before mold closing;

FIG. 5 is a schematic illustration of a fan blade according to an embodiment of the present invention after mold assembly;

FIG. 6 is a first flowchart of a method of manufacturing a fan blade provided by an integrated manufacturing method embodiment of a fan blade of the present disclosure;

FIG. 7 is a second flowchart of a method of manufacturing a fan blade provided by an integrated manufacturing method embodiment of a fan blade of the present invention.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without one or more of these specific details. In other instances, well-known features have not been described in order to avoid obscuring the invention.

Referring to fig. 1, fig. 1 shows a longitudinal cross-sectional view of a fan blade according to the present application. The fan blade of this application includes: the shell 10 is integrally formed by curing composite materials; a foam core mold 20 coated on the shell 10; an interface reinforcing layer 30 sandwiched between the shell 10 and the foam core mold 20; a root bushing 40 is disposed within the root attachment bore 70. The blade root attachment hole 70 may be disposed through the root of the blade in a direction perpendicular to the length of the blade. Wherein fig. 2 shows two root attachment holes 70.

In this embodiment, the casing 10 is the outermost layer structure of the fan blade, and is the main bearing structure of the whole fan blade. The housing 10 needs to have certain strength and corrosion resistance, so that the housing 10 can be integrally formed by curing a composite material. The composite material may include glass fiber prepreg and carbon fiber prepreg. In the process of manufacturing the fan blade, the prepreg can be laid on the foam core mold 20 with a certain shape through a preset laying scheme, and then the foam core mold is placed in a mold to be integrally cured and molded. Of course, the material for manufacturing the housing 10 not only includes the two prepregs, but also meets the requirement of the present invention as long as the material can be integrally cured and molded to form the fan blade.

preferably, this method of manufacturing the housing 10 avoids the prior art method of forming the housing 10 by dividing it into upper and lower portions and then joining them together. Through laying the layer design to blade inner structure and casing 10 and can realizing the whole co-curing shaping of complicated shape blade, can obtain the combined material blade product after the solidification (fan blade root 14 complicated structural feature all is formed with fan blade curing process together), need not secondary operation and cementing, avoided the damage of machine tooling to the combined material structure and combined material to splice the not easily controlled problem of quality. Meanwhile, because the fibers of the front edge of the blade are continuous, the strength of the front edge of the fan blade is higher, and the overall performance of the fan blade is better.

In the present embodiment, since the curing molding pressure of the prepreg after mold clamping is provided by the foam core mold, the foam material should have good compressive creep property, and the material of the foam core mold 20 may include PMI foam and PEI foam. In the process of manufacturing the foam core mold 20, the shape design of the foam core mold 20 can be firstly combined with the appearance of the fan blade, the layer design result and the interference magnitude requirement, so as to obtain a three-dimensional figure file of the foam core mold 20, and then the foam core mold 20 and the blade root connecting holes 70 are processed by a numerical control milling machine according to the corresponding three-dimensional figure file, so as to obtain the foam core mold 20 with the blade root connecting holes 70.

In the present embodiment, and as shown with reference to FIG. 1, the fan blade further includes an interface enhancing layer 30. Wherein the interface enhancing layer 30 is sandwiched between the shell 10 and the foam core mold 20. The material of the interface enhancing layer 30 includes a resin and/or a hot melt adhesive. An interface reinforcement layer 30 bonds the shell 10 and the foam core mold 20 together. Of course, the material of the interface enhancement layer 30 is not limited to the two materials, and is within the scope of the present application, as long as it is sufficient to connect the shell 10 to the foam core 20.

in the process of manufacturing the fan blade, a layer of material of the interface enhancement layer 30 may be laid on the foam core mold 20, vacuum pumping and compaction are performed, and then a prepreg of the shell 10, such as a glass fiber prepreg and/or a carbon fiber prepreg, is laid on the laid interface enhancement layer 30, so that the foam core mold 20 and the shell 10 can be connected through the interface enhancement layer 30, and the fan blade is in an integral structure, thereby improving the overall strength of the fan blade.

In this embodiment, referring to fig. 2 and 3, fig. 2 is a front perspective view of a fan blade provided in an example, and fig. 3 is a side perspective view of the fan blade. To facilitate installation of the fan blade, the fan blade further includes a root bushing 40. A root bushing 40 may be disposed through the shell 10, the foam core 20, and the interface enhancing layer 30. Referring to fig. 3, the housing 10 includes oppositely disposed end portions 12 and a root portion 14. Taking fig. 2 as an example, the left end of the housing 10 is an end portion 12, and the right end is a root portion 14.

Specifically, the fan blade has a rectangular parallelepiped projection 142 at the root 14. Wherein the protrusions 142 can be the shell 10, the interface enhancing layer 30 and the foam core mold 20 from outside to inside, respectively. A blade root attachment hole 70 may be provided in the projection 142. The root bushing 40 is fitted into the root attachment hole 70. Further, in order to fix the root bushing 40 in the root connection hole 70 more stably, at least one interface reinforcing layer 30 may be disposed on an inner wall of the root connection hole 70. When the root bushing 40 is received within the root attachment hole 70, the outer wall of the root bushing 40 may be bonded to the interface enhancement layer 30, such that the interface enhancement layer 30 may secure the root bushing 40 within the root attachment hole 70. The root bushing 40 is inserted through the projection 142. The size and shape of the root attachment hole 70 may be determined based on the actual root bushing 40 to be installed, and is not limited in this application.

In the present embodiment, as shown in fig. 2 and 3, in order to facilitate the installation of the fan blade, the fan blade is further provided with a blade root key groove 50 and a blade root semi-cylindrical groove 60 for matching the installation of the fan blade.

fig. 6 is a first flowchart of a method for manufacturing a fan blade according to an embodiment of the present invention, where the method includes:

S101: forming a foam core mold with a preset shape and blade root connecting holes 70;

Referring to fig. 7, the method may specifically include:

S201: generating a layering scheme according to the stress condition of the fan blade in the working state;

the layering scheme refers to the number of layers of shell prepreg on the foam core mold 20, the specific laying direction, and the specific laying position and shape. For example, how the prepreg is laid in the variable thickness area of the blade, how the fiber angle of each layer is extended, the lap joint or splice position between different layers is determined, and the like. These are determined according to the actual molding scheme, thereby ensuring that the molded housing 10 can be integrally molded while ensuring that the working strength of each part meets the requirements.

the laying scheme can be generated through computer simulation, namely required parameters are input into a computer, the computer generates the laying scheme according to a preset model or program, and technicians can optimize the laying scheme through a trial laying process and lay shell prepreg according to the optimized laying scheme.

S202: generating a three-dimensional graph of the foam core mold according to the shape of the fan blade, the layering scheme and the preset interference magnitude;

for the preset interference magnitude, in the existing fan blade manufacturing process, on one hand, the precise pneumatic shape of the blade is the key for ensuring the efficiency of the fan, and in order to ensure the precise pneumatic shape of the blade, a mold closing molding process is needed to prepare the fan blade, but the problem that the external pressure cannot be applied to the prepreg of the shell 10 after the mold 80 is closed exists. On the other hand. The prepreg curing process of the composite material shell 10 needs a certain forming pressure, the poor glue of the prepreg with too high forming pressure can be caused by improper forming pressure, the prepreg cannot be compacted when the forming pressure is too low, and more interlayer defects are caused to influence the forming quality of the blade

S203: processing a foam core mould with a preset shape according to the three-dimensional graph of the foam core mould;

the foam core mold 20 and the blade root connection hole 70 of a predetermined shape can be machined according to a three-dimensional figure by using a machine tool.

s102: paving an interface reinforcing layer material on the outer surface of the foam core mold and in the blade root connecting hole 70;

After the step of laying the interface reinforcing layer material, vacuum compaction is carried out at room temperature for 20 to 30 minutes.

s103: laying shell prepreg on the outer surface of the interface reinforcing layer material according to a laying scheme to form a blade preformed body;

after each 2 layers of shell prepreg was laid, the blade section width was measured and vacuum-compacted at room temperature for 20 to 30 minutes.

Specifically, after the interface reinforcing layer 30 material is laid, the prepreg of the shell 10 is laid outside the interface reinforcing layer 30 material; after each 2-ply shell 10 prepreg was laid, the blade section width was measured and vacuum-compacted at room temperature for 20 to 30 minutes. When laying casing 10 prepreg, compare with the mode that casing 10 divides the shaping from top to bottom among the prior art, the prepreg of casing 10 can be laid the junction of upper and lower part, and the upper half that is rectangular prepreg can be laid the upper portion at casing 10 promptly, and the lower half can be laid the lower part at casing 10 for the junction of upper and lower part has continuous carbon fiber or glass fiber, and then can guarantee the intensity of junction.

s104: putting the blade preformed body into a mold and packaging the mold;

Referring to fig. 4 and 5, fig. 4 is a schematic view before mold clamping in manufacturing of the fan blade in the embodiment of the present invention, and fig. 5 is a schematic view after mold clamping in manufacturing of the fan blade in the embodiment of the present invention. The preformed body is placed into a lower die of a forming die 80, the preformed body is positioned by a die sliding block, an upper die is closed, the die 80 is pre-positioned by utilizing an upper die groove and a lower die boss, then, a guide rod bolt is used for accurately positioning, an interface reinforcing material is paved on the surface of a blade root metal bushing and then assembled into a blade root connecting hole 70 together with a hole die, a key die is sequentially installed, and the blade root die is positioned to complete the assembly of the die 80. The mold 80 may be encapsulated with a barrier film, air felt, and vacuum bag in sequence.

S105: putting the packaged die into an autoclave for heating, pressurizing and curing;

the heating temperature can be 120-140 ℃, and when the temperature in the autoclave is reduced to be below 60 ℃, the fan blade in an integrated structure can be obtained.

S106: demolding to obtain the fan blade with the sandwich structure;

After the temperature in the heating tank is reduced to room temperature, according to the reverse steps when the mold is packaged, the packaged mold can be disassembled, and then the fan blade is taken out, so that the demolding of the fan blade is completed.

According to the invention, through the optimized design of the layering scheme of the fan blade and the interference fit of the mold, the integrated manufacturing method of the fan blade can avoid the molding mode that the shell 10 is divided into an upper part and a lower part for molding and then connected together in the prior art. Meanwhile, the overall co-curing molding of the blades with complex shapes can be realized by laying the layer design on the internal structure of the blades and the shell 10, and the composite material blade product can be obtained after curing (the complex structural characteristics of the root part of the fan blade are formed together with the curing process of the fan blade), so that the secondary processing and the bonding are not needed, the problems that the composite material structure is damaged by machining and the bonding quality of the composite material is not easy to control are solved, and the overall performance of the fan blade is better.

The present invention has been illustrated by the above embodiments, but it should be understood that the above embodiments are for illustrative and descriptive purposes only and are not intended to limit the invention to the scope of the described embodiments. Furthermore, it will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that many variations and modifications may be made in accordance with the teachings of the present invention, which variations and modifications are within the scope of the present invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.