• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Compaction assembly comprising a shaping mold (24) delimiting an upwardly open housing, adapted to receive a pre-cut woven preform (10a), and a compaction tool (128) vertically movable and forming, with the shaping mold ( 24), a compaction assembly of said preform previously placed in the housing. The compaction tool (128) has at least one foot portion (128A). Application to the manufacture of turbomachine composite blades.
    公开号:FR3022829A1
    申请号:FR1456021
    申请日:2014-06-27
    公开日:2016-01-01
    发明作者:Yann Marchal；Matthieu Gimat
    申请人:SNECMA SAS；
    IPC主号:
    专利说明:

    [0001] The present disclosure relates to a compaction assembly and a method for the manufacture of a composite turbomachine blade, as well as to a composite turbomachine blade. COMPOUNDING ASSEMBLY AND METHOD FOR MANUFACTURING A TURBOMACHINE COMPOSITE DRAWING The composite blade may be a blade of the type comprising a three-dimensional woven wire or fiber preform and a binder maintaining the relative disposition between the preform wires. Said preform may be formed of warp son and weft son, the direction of the warp son forming the longitudinal direction of the preform. In particular, the present method relates to the manufacture of a fan blade for a turbomachine, in particular a turbojet engine. However, it is also envisaged to manufacture a blade for a low pressure compressor where the temperatures reached in operation are compatible with the thermomechanical resistance of this type of blade. It is also envisaged to manufacture non-ducted fan blades (or "open rotor") or blades with integrated platform. BACKGROUND 20 In the usual manner, the blades of blowers made of composite material, in particular of carbon fibers, are made from a stack of pre-impregnated unidirectional folds which are placed in a mold by orienting the plies differently. successive, before compacting and autoclave polymerization. This very delicate technique requires manual stacking operations which are time consuming and costly. It has also been proposed to prepare dry fiber woven preforms which are then sewn together prior to resin impregnation by injection into a closed mold. An alternative has been to make a single woven preform that is mounted with one or more solid inserts prior to injection. These solutions (patent documents US 5,672,417 and US 5,013,216) however have the disadvantage of requiring the assembly of several parts and create in these assembly areas, preferred sites of fragility, for example delamination, 5 which is very harmful in terms of mechanical strength, especially for impact resistance. In order to overcome these drawbacks, patent document FR 2 861 143 proposed to produce a preform made of three-dimensionally woven fibers or yarns which can be used to form the final piece on its own, after any cutting and injection of the binder. forming all parts of the turbomachine blade, without recourse to the use of inserts or any other element reported. In particular, the manufacturing method shown in patent document FR 2 892 339 is used, in which the woven and then cut preform is shaped in a mold before injecting the binder and curing the latter. However, there are still a number of problems with how this formatting is done. GENERAL PRESENTATION The present disclosure relates to a compaction assembly to avoid the aforementioned drawbacks. In particular, this compacting assembly makes it possible to pre-compact the preform. This compacting assembly may be used for a preform obtained by three-dimensional weaving of yarns and intended to form a composite turbomachine blade, said preform comprising both the blade, the root of the blade and, between the blade and the blade. foot, the stilt of dawn. This compacting assembly comprises a shaping mold defining an upwardly open housing, for receiving a woven preform (which may be previously cut), and a vertically movable compaction tool cooperating with the shaping mold to form a compaction assembly allowing compacting said preform when placed in the housing. The compacting assembly may define a longitudinal direction and a vertical median plane parallel to the longitudinal direction.
    [0002] The compacting tool may be configured to descend toward the conformation mold. The compaction tool includes at least a foot portion. For example, the compacting tool may comprise a foot portion only, or it may comprise a foot portion and a stilt portion. In the latter case, the foot portions and stilt can form a one-piece assembly or, conversely, be separated from one another. When separated, the stilt portion may itself be divided into at least three separate compaction blocks, including a central compaction block, said compaction blocks being configured to descend to the conformation mold so that independent. In particular, the compacting blocks can be descended sequentially, starting with the central compacting block. The present disclosure also relates to a method for manufacturing a turbomachine composite blade using a compaction assembly, and a composite turbomachine blade. BRIEF DESCRIPTION OF THE DRAWINGS Other advantages and characteristics of the invention will emerge on reading the following description referring to the appended drawings in which: FIG. 1 is a general perspective view of an example of a preform, after cutting, FIG. 2 illustrates a step of producing an exemplary manufacturing method, FIGS. 3 and 4 are sectional views along directions III and IV of FIG. 2, showing the effect of compaction on the profile of two different portions of the preform, with a compaction assembly according to a first embodiment of the invention, - Figure 5 is a partial view of the preform of Figure 1, showing an enlarged foot and stilt, - FIG. 6 is a sectional view similar to that of FIG. 4, showing another example of a compaction assembly, FIG. 7 is a perspective view of the compaction tool of the compaction assembly of FIG. , - Figures 8 and 9 are comparative schematic representations of parts of composite blades, these blades having been manufactured differently. Figures 10 and 11 illustrate how to measure the deflection angle of two fibers having two typical buckling configurations. DETAILED DESCRIPTION OF EXAMPLE (S) Exemplary embodiments are described in detail below, with reference to the accompanying drawings. These examples illustrate the features and advantages of the invention. However, it is recalled that the invention is not limited to these examples. According to an exemplary implementation, the manufacturing process begins with a first step a) consisting in producing a three-dimensional preform by weaving, the woven preform comprising warp yarns 20a and weft yarns 20b. In these two groups of son, there are provided tracer son 22 visually identifiable from other son and regularly located at least on the surface of the preform. The warp and weft threads may belong, for example, to the group consisting of carbon fibers, glass fibers, silica fibers, silicon carbide fibers, alumina fibers, aramid fibers and fibers. aromatic polyamides. The one-piece woven preform is then cut according to a second process step b). More exactly, this woven preform is cut off by cutting the contour according to a predetermined three-dimensional abacus provided for after the deformation, the preform respects the geometry of the finished part. This cutting can be performed by water jet and / or by mechanical means (scissors, cutter, saw ....) and / or by laser cutting. The result is a cut-out preform 10a visible in FIG. 1. The parts intended to form the blade 12 and the root 14 of the blade 10, as well as the stilt 13 which is the transition part between the blade 12 and the foot 14. In particular, the warp yarns 20a and the weft yarns 20b used for the three-dimensional weave are carbon fibers (black) and glass fibers or Kevlar (white) form tracer son 22 located essentially at the surface of the preform, along the longitudinal main direction parallel to the warp yarns 20a and along the transverse direction parallel to the weft yarns 20b. In this way, the tracer son 22 appear white on the remainder of the preform which is black, and the tracer son 22 are therefore very visible. In addition, these tracer son are detectable by conventional non-destructive testing technologies (such as X-ray tomography or ultrasound) to verify the conformity of the final part. In particular, these tracer wires 22 are present here on the surface of the two faces (respectively intended to form the lower face wall 17 and the upper surface 18) of the blade at predetermined locations in order to serve as a reference point. for positioning for cutting and other processing steps of the preform, as discussed below. During this cutting step, it is intended to keep a series of tracer son 22 located on the surface of the preform along at least one reference face 16, which in the case illustrated is the face intended to form the edge 30 of attack. 3022 82 9 6 Then, a pre-deformation of the cut preform 10a is carried out during a step c). In particular, during step c), said pre-deformation is carried out by placing the cut preform 10a in a shaping mold 24 (FIG. 2) having different portions delimiting between them a cavity (housing 26) intended to house the cut preform. 10a and having reference marks for the positioning of at least some of the tracer son 22. Various systems for locating and positioning the cut preform 10a can be used, in particular a laser projector 27 (see FIG. 2) which projects a light beam at the ideal location of a tracer wire 22 so that it is then easy to move the corresponding tracer wire 22 accordingly to obtain the predetermined positioning. Alternatively or additionally, masks, taking up the contour 15 and / or the position of all or part of the tracer son 22, may be arranged on the preform to control its proper positioning. When disposing the cut preform 10a in the conformation mold 24, the cut preform 10a is placed in a configuration which deforms it applying a rotation (arrow 25a in FIG. 2) around an axis 0 ('parallel to its main direction, which has the effect of twisting the blade around this axis In some cases, it is also possible that the shaping mold 24 has a movable portion 24a, sliding and intended to be positioned against the free end foot 14 of the preform in order to come to exert a constraint (arrow 25b in FIG. 2) realizing the desired deformation of this portion 14 of the preform, or avoiding certain types of deformation in this part while one exerts a deformation on Other Portions of the Preform 10b It is to be understood that many different possibilities are conceivable for conforming the cut preform 10a through the use of the preform 10b. tracer son 22 as reference elements for positioning the preform 10a in the conformation mold 24. The placement strategy of the cut preform 10a in the conformation mold 24 is also related to the cutting or trimming profile 5 previously produced, according to the or the selected reference surface (s), in particular among the foot, the head, the leading edge 16, the trailing edge 19 or any other predetermined zone. Placing the cut preform 10a in the shaping mold 24 may be sufficient to achieve all the deformations necessary to achieve the final desired shape. However, in some cases, this step c) can also be carried out in several sub-steps. Next, a binder comprising a thermosetting resin is injected into said injection mold so as to impregnate the entire preform and maintain the relative disposition between the preform wires; said injection mold is heated; and leaving the mold a composite molded part having substantially the shape and dimensions of said blade. In a step d) which follows step c) and before carrying out the injection of the binder, a pre-compacting of at least a portion of the pre-deformed preform 20 is carried out, comprising the foot and preferably the foot 14 and the stilt 13, over the entire width of the pre-deformed preform 10b. This pre-compacting blocks certain fibers in a desired position, or at least limits their possibilities of movement, resulting in an intermediate geometry of the preform, which is even closer to the desired final shape. The fact of blocking in position the fibers of the foot and preferably, those of the stilt, ensures a better positioning of the fibers in the blade manufactured and allows, in particular, to limit the phenomenon of buckling fibers usually found in these parts of dawn. The good positioning of the fibers makes it possible, in turn, to obtain good mechanical properties in the foot and stilt of the dawn. Such an advantage is particularly interesting because the foot and stilt are the parts of the blade most mechanically stressed in operation. The compacting tool 28 used for this purpose, visible schematically and partially in FIG. 2, can be produced by completing the shaping mold 24 with the necessary equipment. Indeed, the compaction tool 28 is movable (up and down) and must be able to be heated to a temperature of the order of 100 ° C. During this step d), it is the sizing products coating the yarns and which are used to facilitate the weaving, which allow the blocking of the relative position of the fibers of the pre-compacted portion. Subsequently, wetting of the pre-compacted preform 10c is carried out and drying is carried out, for example in an oven, whereby a stiffened preform is provided. In fact, this stiffening will sufficiently freeze the conformation given in step c) to the cut preform 10a, which has become the pre-deformed preform 10b, so that it can be placed later easily in the injection mold. 24 without substantially changing its shape which corresponds to that of the aforementioned pre-deformation. If necessary, it may be possible to add a tackifier inside the preform, for example a dilute resin, in particular of the epoxy type, the whole being capable, under the effect of the heat and the pressure exerted during the pre-compacting step d), bonding the woven carbon fibers together to prevent the pre-deformed preform 10b from undergoing any subsequent deformation, in particular during the injection step. The compacting tool 28 has a shape and dimensions that allow it to be inserted into the housing 26 of the conformation mold 24 to allow the woven preform to be compacted at an intermediate fiber volume ratio with respect to the final fiber volume ratio. of the final piece. For example, with the compacting tool 28, it is intended to produce a compacted preform having a fiber volume content of between 35% and 55%, so that the final part, after injection, has a fiber volume content between 50% and 65%. Referring to Figures 3 and 4, showing in cross section a compaction assembly according to an embodiment (shaping mold 24 and compacting tool 28) and the pre-deformed preform 10b at the foot 14 (Figure 3) and stilt 13 (Figure 4), to understand how the pre-deformation is applied to these parts 13, 14 different from the pre-deformed preform 10b (line dashed lines) to reach the compacted preform 10c (solid line) For the foot 14 (Figure 3), the housing 26 of the shaping mold 24 has a rectangular section and the compaction tool 28 has a foot portion 28A whose rectangular section is complementary to that of the housing 26.
    [0003] For the stilt 13 (Figure 4), the housing 26 of the shaping mold 24 has a section with a convex bottom 26a and flared sides 26b towards the opening of the housing 26. The compaction tool 28 has a portion stagger 28B whose section comprises substantially vertical sides 28b and a bottom 28a, intended to come opposite the convex bottom of the shaping mold 24. This bottom 28a is concave with a profile having larger radii of curvature than the profile convex of the bottom of the housing 26 of the conformation mold 24. The compacting tool 28 according to this embodiment is monoblock so that during its movement, it descends (or rises) entirely in (or from) the housing 26 of the conformation mold 24, thereby compressing the pre-deformed preform 10b. To avoid damaging the fibers of the pre-deformed preform 10b, and in particular to pinch them, the surfaces of the conformation mold 24 and the compacting tool 28 turned towards the housing do not have any sharp or steep ridge but consist of faces with angles softened by rounded or radiated connections forming fillets. In such a situation, when the compaction tool 28 goes down, considering the stag portion 28B compressing the stalk 13 of the preform (FIG. 4), it is firstly the lateral edges 16a and 19a. of the pre-deformed preform 10b, intended to form respectively the leading edge 16 and the trailing edge 19, which come into contact with the compaction tool 28 at the location of the side edges 28c of the bottom 28a. Then, the contact is made progressively with all the surface of the stilt 13 turned facing the compaction tool 28, ending with the central zone (band) of this surface, this central zone passing through a median plane PM of the compacting set. This median plane PM, which is not necessarily a plane of symmetry for the compaction assembly and for the preform, is vertical, parallel to the axis 0 (oriented in the main direction of the preform, and is midway between the lateral edges 26b of the housing 26 of the shaping mold 24 and between the lateral edges 28b of the compaction tool 28. This configuration may sometimes have certain disadvantages with regard to the pre-deformation of the stilt 13: thus, in the case illustrated in Figure 5, the side edges 16a and 19a of the pre-deformed preform 10b being on the one hand thinner in thickness and undergoing a greater bending than the rest of the staggered, the fibers 20 forming the preform undergo buckling, which can be detrimental to the good thermomechanical strength of the final blade.
    [0004] The zones of the cut preform 10a which undergo this undesirable buckling are indicated in FIG. 5 at the two locations Z1 and Z2 corresponding to the thin edges of the stilt 13 situated near the blade 12. To overcome the aforementioned drawbacks, according to an embodiment, the compaction tool may comprise at least three separate compacting blocks, among which a central compaction block passing through said median plane and two lateral compacting blocks located at the lateral ends of said compacting tool, said blocks of compacting compaction being able to descend one by one in the direction of the conformation mold independently, starting with the central compacting block. In this way, the compaction tool can be formed of at least three parts and can be moved down at different times, starting with the central compaction block that goes down first so that the first contact between the compacting tool and the cut preform is made at the central area of the stilt surface facing the compaction tool. In this way, thanks to the compaction assembly of the invention, the lateral edges of the stilt of the preform are compacted last, which makes it possible to minimize or even avoid the buckling of fibers in these zones. low thickness during pre-compaction. In particular, the compacting tool may comprise an odd number of separate compacting blocks, so as to form a geometry with a central compacting block passing through said median plane and on either side of this central compacting block, an identical number of other compaction blocks. A multi-block compaction tool has the advantage of allowing, in addition, to measure the precompaction level exerted by each of the compacting blocks on the preform, which can be measured by the volume ratio of intermediate fibers resulting from this pre-compaction.
    [0005] In some embodiments, said compacting blocks are adapted to descend one by one towards the conformation mold in an order that compresses the entire width of said preform starting with said central compacting block and then each compacting block adjacent to that previously descended to the side compacting block. In some embodiments, said compaction tool includes at least a foot portion and a stilt portion and the stilt portion has at least three separate compaction blocks. The foot portion can, for its part, be multiblock or monobloc. When the foot portion is multiblock, it can be divided into at least three separate compaction blocks, including a central compaction block. In some embodiments, said compaction blocks are adapted to descend toward the shaping mold, beginning with the central compaction block, then all compaction blocks on one side of the median plane, preferably one by one and gradually from the central compacting block to the first lateral compacting block, and finally all the compacting blocks on the other side of the median plane, preferably one to one and step by step from the central compaction block to the second lateral compaction block. According to an alternative possibility, said compacting blocks are able to descend towards the conformation mold symmetrically with respect to the median plane. In some embodiments, the entire compaction tool 128 is divided into at least three separate compaction blocks, including a central compaction block 1281 passing through the center plane PM of the compaction tool 128, said compaction blocks being able to descend towards the shaping mold 24 independently, starting with the central compacting block 1281. The compaction tool 128 may include the transition zone between the foot 14 and the blade 12, namely the stilt 13, and this to control the deformations induced by compaction in this transition zone. For this purpose, the stag portion 128B of the compaction tool 128 can go up in the stilt 13, up to a height of more than 50 mm and preferably about 70 mm above the staves 14b (see figure 1). In the example of FIGS. 6 and 7, the compaction tool 128 comprises a separate foot portion 128A and a stag part 128B. The foot portion 128A and the stag portion 128B thus constitute independent portions of the compaction tool. In particular, as illustrated, the foot portion 128A may be one-piece and the stag portion 128B may have at least three separate compaction blocks, including a central compaction block 1281 passing through the center plane PM of the tool compacting member 128, said compacting blocks separated from the staggering portion 128B being able to descend towards the shaping mold 24 independently, starting with the central compacting block 1281. In the example, the portion Stag 128B of the compaction tool 128 is divided into seven separate compaction blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287, distributed around and on either side of the median plane PM. In this way, the downward movement of compaction tool 128 can be decomposed. For example, foot portion 128A and stile portion 128B can be independently lowered. The stilt portion 128B can, in turn, be lowered starting with the central compaction block 1281 passing through the center plane PM of the compaction tool 128 (downward arrow D1 and dashed line 1281 'in the figure 6), then the two compaction blocks 1282 and 1283 located on either side of the central compaction block 1281 (downward arrows D2 and D3 and dashed lines 1282 'and 1283' in FIG. 6), and thus continued to the two lateral compaction blocks 1286 and 1287 at the lateral ends of the compaction tool 128. In this embodiment, the descent movement of the single foot block constituting the foot portion 128A is, for example initiated before the beginning of the descent of the central compaction block 1281 of the stag portion 128B, or at the same time at the beginning of the descent of the central compaction block 1281 of the stag portion 128B with a velocity 3022 82 9 14 different e or equal to that of the central compacting block 1281 of the stilt portion 128B. Alternatively, the descent movement of the single foot block constituting the foot portion 128A can be fully realized before the beginning of the descent of the central compaction block 1281 of the stag portion 128B: in this way, can block the foot before handling the rest of the preform. This embodiment makes it possible to manage the shape given to the foot 14 of the pre-deformed preform 10c, by the shape of the lower face of the foot block 128A, and its compaction rate, by the adjustment of the force exerted in the lowest position, autonomously to those of the stub block 128B: this configuration facilitates obtaining a compaction rate of the staves (side faces of the foot 14) satisfactory in the final part. In addition, locking the fibers of the foot 14 in position (or at least limiting their possibilities of movement) by means of the foot block 128A before compacting the stilt 13 by means of the stub block 128B improves still the positioning of the fibers in the manufactured dawn. This aspect associated with lowering the compacting blocks 1281 to 1287 to the conformation mold independently, beginning with the central compacting block, significantly reduces the undesirable buckling phenomenon at the zones Z1 and Z2, identified in fig. 5 and corresponding to the thin edges of the stilt 13 located near the blade 12. The comparative representations of FIGS. 8 and 9 illustrate this result. The representation of FIG. 8 shows a composite blade comprising a binder impregnated three-dimensional preform, which now binds the relative arrangement between the fibers of the preform. This blade was manufactured according to the method described below, from a pre-compacted preform using a compacting tool 28 monoblock such as that of FIG. 2. The outer layer of the woven preform is visible in FIG. 8. The dawn area shown in FIG. 8 corresponds to the zone Z1 marked 3022 82 9 15 in FIG. 5, that is to say to the zone of the stilt 13 which runs along the leading edge and which is adjacent to the blade 12. In this zone Z1, the edge of the stilt 13 is particularly thin. Several inscriptions have been plotted on the represented surface of the preform 10, whose lines Li and L2. These lines L1 and L2 were plotted respectively following two fiber portions F1 and F2 of the outer layer of the woven preform 10. The main direction of the fibers F1, F2 is substantially vertical in FIG. 8. The Li and L2 lines, which locally represent the trajectory of the two fiber portions F1 and F2, are curved, illustrating that the fibers F1 and F2 deviate from their main direction locally. We are talking about the buckling of the fibers Fl and F2 to designate such a phenomenon. Buckling is quantified by measuring the Al deflection angle of the fibers F1 and F2. Figures 10 and 11 respectively illustrate how this angle A1 is measured for two fibers F in two typical buckling configurations. In the case of buckling 15 marked in FIG. 8 by the lines L1 and L2, the deflection angle Al of the fibers F1 and F2 is at least 30 °. Fig. 9 is a representation similar to that of FIG. 8 showing a composite blade comprising a three-dimensional woven preform impregnated with binder. This blade was made by the same method as that of FIG. With the exception of the pre-compacting step of the preform 10. Here, the preform 10 has been pre-compacted by means of a compaction tool 128 such as that of FIG. 7. The outer layer of the woven preform is visible in FIG. 9. The area of the dawn shown in fig. 9 corresponds to the zone Z1 marked in FIG. 5. A line L3 has been drawn 25 following a portion of a fiber F3 belonging to the outer layer of the preform 10. It has been observed a lack of buckling, or at least a limited buckling for the F3 fiber and all adjacent fibers located in zone Z1. In particular, it has been found that the deflection angle λ1 of the fibers in this zone Z1 was less than 20 ° and more particularly less than 5 °. Similar findings have been made in the Z2 area marked in FIG. 5, that is to say in the zone of the stilt 13 which runs along the trailing edge and which is adjacent to the blade 12. In some embodiments, the compacting tool 128 further comprises a deformable skin 130 (for example a thick film of silicone) 5 which covers at least the entire face of said stag portion 128B of the compaction tool 128 intended to be turned facing the shaping mold 24. In the example of FIG. 6, this deformable skin 130 covers almost the entire compacting tool 128. According to a variant not shown, this skin covers only the stag portion 128B of the compaction tool 128, only the face of said portion stitch 128B of the compaction tool 128 facing the conformation mold 24, all faces of said stagger portion 128B. As can be seen in FIG. 6, with such a flexible skin 130, it is possible not to hinder the progressive descent movement of the separate compacting blocks 1281, 1282, 1283, 1284, 1285, 1286 and 1287, thanks to deformation and reversible extension of this skin 130 (see the deformed 130 'of the skin), while avoiding the pinch weft son 20 20a or 20b warp son of preformed preform 10b. As illustrated in FIG. 7, optionally, the compaction tool 128 comprises at least one window 132 making it possible to visualize the position of at least one tracer wire when the preform is placed in the housing delimited between the conformation mold 24 and the compacting tool 28. This window 132 consists for example of a portion of the compacting tool 128 made of a transparent material, or preferably an opening through the entire thickness of the compacting tool 28. This window 132 may be disposed in an area of the stilt portion 128B which is adjacent to the foot portion 128A, preferably at the central compaction block 1281. Such a window 3022 allows for example to verify that the tracer son (s) 22 visible by this window (for example the range exit plotter wire) are correctly positioned and remain so during the compacting operation. In the example illustrated in FIG. 6, the stag portion 128B of compaction tool 128 is divided into seven separate compaction blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287. The compacting blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287 may also descend to compact the preform 10b with different speeds and / or forces exerted by these compaction blocks on the preform which are different from each other. where precompaction levels or volume levels of intermediate fibers resulting from this precompaction which are different between the compacting blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287. In the illustrated example, there is seven compaction blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287 for the stag portion 128B, but in general, at least five, for example exactly five, can be provided, and that the division into separate compaction blocks concerns the (unitary) assembly formed by the stag portion 128B of the compaction tool 128 and the foot portion 128A of the compaction tool or only the stag portion 128B of the compaction tool 128. A method of manufacturing a A composite turbomachine ube may comprise the following steps: a) a preform 10 is made by three-dimensional weaving of threads 20a, 20b, 22, said preform comprising both blade 12, foot 14 of dawn and , between the blade 12 and the foot 14, the stalk 13 of the blade, the son 20 comprising visually identifiable tracer son 22 arranged at least on the surface of the preform; b) said preform is cut by leaving intact a series of tracer wires 22 situated along a reference face 16 of the preform, whereby a cut preform 10a is provided which can take the shape and dimensions of the constituent parts of the preform, dawn ; c) preforming said cut preform 10a, whereby a predeformed preform 10b is provided; d) pre-compacting of said preformed preform 10b, whereby a pre-compacted preform 10c is provided; e) wetting of the pre-compacted preform 10c is performed and drying is carried out, for example in an oven, whereby a stiffened preform 10 is provided; f) an injection mold 24 is provided in which said rigidified preform 10 is placed; g) injecting into said injection mold a binder comprising a thermosetting resin so as to impregnate all the preformed rigidified preform 10 and maintain the relative disposition between the son 20a, 20b, 22 of the stiffened preform; h) heating said injection mold; and i) leaving the mold a composite molded piece having substantially the shape and dimensions of said blade. During step c), said predeformation is carried out by placing the cut preform 10a in the housing 26 defined by a shaping mold 24 and during step d) said pre-compaction of said pre-deformed preform 10b is carried out using a compaction tool 128 movable and cooperating with the shaping mold 24 to form a compacting assembly defining a longitudinal direction and a vertical median plane PM parallel to the longitudinal direction. During step d), the compaction tool 28 can descend towards the shaping mold 24. When the compaction tool 128 comprises several compaction blocks 1281, 1282, 1283, 1284, 1285, 1286, 1287 as previously described, the compacting tool 128 is able, during step d), to compact at least the foot 14 of said pre-deformed preform 10b starting from the middle and progressively going to the edge of the preform pre -formed 10b. Also, when the compaction tool 128 comprises a leg portion 128A and a stag portion 128B as previously described, these portions 128A, 128B may descend toward the conformation mold 24 separately. Thus, thanks to these advantageous arrangements, it avoids fiber buckling in the foot zone 14 and the staggering zone 13 of the preform during the compaction step, which is illustrated in part in FIGS. 8 and 9. previously described. In this process, during step d), said compacting tool 128 is able to descend towards the conformation mold 24 so that said compacting units descend one by one towards the conformation mold 24 in an order that compacting the entire width of said preform 10b starting with its central portion passing through the median plane PM and each adjacent portion to the previous, progressively deviating from the median plane PM. During step d), said compaction tool 128 may be able to descend towards the shaping mold 24 symmetrically with respect to said median plane PM. In the figures, there is shown the case of a foot 14 which remains rectilinear throughout the manufacturing process. It is understood that without departing from the scope of the present invention, it is possible to envisage the case of a foot which is twisted, or deformed according to any other action, when it is placed in the conformation mold 24. Moreover, according to a variant embodiment not shown, the compaction tool 128 covers not only the foot 14 and the stilt 13 of the blade, but also a portion of the blade 12 of the blade. Also, in the foregoing description, it has been mentioned that compaction tool 128 performs a precompaction step, i.e., step d).
    [0006] However, it is also possible to use this compaction tool 128 alternately as an element of the injection mold 24 and use it only for steps f) and g). According to another variant, this same compaction tool 128 can be used both for step d) of precompaction and for steps f) and g). The verb "to understand", when used in the present application, should be interpreted to mean the presence of the stated characteristic, but does not exclude the presence or addition of one or more other characteristics.
    [0007] The modes or examples of embodiment described in the present description are given for illustrative and not limiting, a person skilled in the art can easily, in view of this presentation, modify these modes or embodiments, or consider others, while remaining within the scope of the invention. In addition, the various features of these modes or embodiments can be used alone or be combined with each other, the invention is not limited to the specific combinations described in this presentation.
    权利要求:
    Claims (13)
    [0001]
    REVENDICATIONS1. Compaction assembly for a woven preform obtained by three-dimensional weaving of yarns (20) and intended to form a composite turbomachine blade, said preform comprising predefined parts of the blade (12), the foot (14) of the blade and between the blade (12) and the foot (14), the stilt of the blade (13), the compacting assembly comprising a conformation mold (24) defining a housing (26) open upwards, suitable receiving a woven preform (10a), and a compaction tool (28) vertically movable and cooperating with the conformation mold (24) to form a compacting assembly for compacting said preform (10b) when placed in the housing (26), wherein the compaction tool (28) comprises at least one foot portion (128A).
    [0002]
    The compacting assembly of claim 1, wherein said compaction tool (28) further comprises at least one stilt portion (128B).
    [0003]
    The compaction assembly of claim 2, wherein the foot portion (128A) and the stag portion (128B) are separated.
    [0004]
    The compaction unit of claim 3, wherein the foot portion (128A) and / or stilt portion (128B) is divided into at least three separate compaction blocks (1281-1287), including a block central compacting unit (1281), said compacting blocks (1281-1287) being configured to descend toward the conformation mold (24) independently, starting with the central compacting block (1280. 3022 82 9 22
    [0005]
    The compaction assembly of claim 3 or 4, wherein the foot portion (128A) is integral and wherein the stilt portion (128B) is divided into at least three separate compaction blocks. 5
    [0006]
    6. compacting assembly according to any one of claims 1 to 5, further comprising a deformable skin (130) covering at least a portion of the compacting tool in front of the conformation mold (24). 10
    [0007]
    7. compaction assembly according to claim 6, wherein the deformable skin (130) covers at least the entire surface of the stilt portion in front of the conformation mold.
    [0008]
    The compaction assembly of any one of claims 1 to 7, wherein the compaction tool (128) has at least one window (132) configured to view the position of at least one tracer wire (22). when the preform is placed in the housing (26).
    [0009]
    9. A method of manufacturing a composite turbomachine blade, comprising the following steps: a) a preform is made by three-dimensional weaving of wires (20a, 20b, 22), said preform comprising portions defining the blade (12). ), the foot (14) of the blade and, between the blade (12) and the foot (14), the stilt of the blade (13), the son (20a, 20b, 22) comprising tracer son (22) visually identifiable at least on the surface of the preform; b) said preform is cut by leaving intact a series of tracer wires (22) located along a reference face (16) of the preform, whereby a cut preform (10a) configured to predefine the shape and shape is obtained; the dimensions of the constituent parts of the dawn; 302 2 82 9 23 c) pre-deforming said cut preform (10a), whereby a pre-deformed preform (10b) is obtained; d) pre-compacting said pre-deformed preform (10b) whereby a pre-compacted preform (10c) is obtained; E) the pre-compacted preform (10c) is wetted and dried, whereby a stiffened preform is obtained; f) providing an injection mold in which is placed said stiffened preform; g) injecting into said injection mold a binder comprising a thermosetting resin to impregnate the entire stiffened preform and maintain the relative disposition between the wires (20a, 20b, 22) of the stiffened preform; h) heating said injection mold; and i) a composite molded piece having substantially the shape and dimensions of said blade is removed from the mold, wherein during said step c) said pre-deformation is carried out by placing the cut preform (10a) in a housing (26) delimited by a shaping mold (24) and in that during step d) is carried out the precompaction. 20
    [0010]
    10. The method of claim 9, wherein, in step d), at least the foot portion (12) of the preform is pre-compacted (10b).
    [0011]
    11. A process according to claim 9 or 10, wherein during steps c) and d) a compaction unit according to any one of claims 1 to 8 is used.
    [0012]
    12. Turbomachine composite blade having a foot (14), a blade (12) and a stilt (13) constituting a transition leg between the foot (14) and the blade (12), the blade comprising a fiber preform woven interleaved dimensions compacted and impregnated with binder, the fibers of the outer layer of the preform, located in the area of the stilt (13) adjacent to the blade (12) and along the leading edge or trailing edge of the dawn, having a deflection angle (A1) of less than 20 °.
    [0013]
    13. A turbomachine comprising a composite blade according to claim 12.
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    同族专利:
    公开号 | 公开日
    CN105592995A|2016-05-18|
    FR3022829B1|2017-02-24|
    WO2015049475A1|2015-04-09|
    CA2926069A1|2015-04-09|
    EP3052286A1|2016-08-10|
    JP6397006B2|2018-09-26|
    US20160243777A1|2016-08-25|
    RU2016117170A3|2018-05-17|
    CA2926069C|2021-08-31|
    RU2016117170A|2017-11-10|
    RU2671736C2|2018-11-06|
    US10569489B2|2020-02-25|
    BR112016007445A2|2017-08-01|
    JP2016539819A|2016-12-22|
    CN105592995B|2018-08-10|
    EP3052286B1|2020-07-15|
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    法律状态:
    2015-06-12| PLFP| Fee payment|Year of fee payment: 2 |
    2016-01-01| PLSC| Search report ready|Effective date: 20160101 |
    2016-06-10| PLFP| Fee payment|Year of fee payment: 3 |
    2017-04-27| PLFP| Fee payment|Year of fee payment: 4 |
    2017-11-10| CD| Change of name or company name|Owner name: SNECMA, FR Effective date: 20170713 |
    2018-06-05| PLFP| Fee payment|Year of fee payment: 5 |
    2020-05-20| PLFP| Fee payment|Year of fee payment: 7 |
    2021-05-19| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1456021A|FR3022829B1|2014-06-27|2014-06-27|COMPACTING ASSEMBLY AND METHOD FOR MANUFACTURING A TURBOMACHINE TURBINE COMPOSITE|FR1456021A| FR3022829B1|2014-06-27|2014-06-27|COMPACTING ASSEMBLY AND METHOD FOR MANUFACTURING A TURBOMACHINE TURBINE COMPOSITE|
    BR112016007445-9A| BR112016007445B1|2013-10-04|2014-10-03|COMPACTION ASSEMBLY TO COMPACT A WOVEN PREFORM, METHOD FOR MANUFACTURING A COMPOSITE TURBOMACHINE BLADE, COMPOSITE TURBOMACHINE BLADE, AND, TURBOMACHINE|
    US15/026,282| US10569489B2|2013-10-04|2014-10-03|Compacting assembly and method of fabricating a composite blade for a turbine engine|
    EP14789326.7A| EP3052286B1|2013-10-04|2014-10-03|Compacting assembly and method for manufacturing a turbomachine composite blade|
    CA2926069A| CA2926069C|2013-10-04|2014-10-03|Compacting assembly and method for manufacturing a turbomachine composite blade|
    JP2016519804A| JP6397006B2|2013-10-04|2014-10-03|Compression assembly and method for manufacturing composite blade for turbine engine|
    PCT/FR2014/052515| WO2015049475A1|2013-10-04|2014-10-03|Compacting assembly and method for manufacturing a turbomachine composite blade|
    RU2016117170A| RU2671736C2|2013-10-04|2014-10-03|Compacting device and method of manufacturing turbomachine composite blade|
    CN201480055009.0A| CN105592995B|2013-10-04|2014-10-03|Compacting component and method of the manufacture for the composite blading of turbogenerator|
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