• 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:
    The invention relates to a method for manufacturing a propeller blade (10, 12), said blade comprising an outer casing (26) and an inner cavity (32). The method comprises a step of first depositing a material (22) in successive layers on a support (18), so as to define a section of the outer envelope and walls (30) of the internal cavity. The method then comprises the following steps: - assembling the deposited material (22) with an insert (34) in contact with an end of the internal cavity, so as to close said internal cavity; then - second deposit of material (33) in successive layers, so as to completely coat the insert with the deposited material. The invention further relates to a propeller blade thus obtained.
    公开号:FR3027243A1
    申请号:FR1402334
    申请日:2014-10-16
    公开日:2016-04-22
    发明作者:Guillaume Philippe Jean Patrick Ruckert；Francois Bernard Cortial
    申请人:DCNS SA；
    IPC主号:
    专利说明:

    [0001] The present invention relates to a method of manufacturing a propeller blade, said blade comprising a body disposed along an axis, said body comprising an outer envelope and one or more cavities (s). ) disposed along the axis, the method comprising a step of first deposition of a material in successive layers on a support, said layers being stacked along the axis, so as to define a section of the external envelope and walls of the cavity (s) internal (s). The invention involves additive manufacturing technology by directed energy deposition. The principle of this additive manufacturing is the formation of a piece by successive slices. The formation of a wafer comprises the deposition of a layer of a material, for example in powder form, followed by the local melting of said material in a shape corresponding to a section of the workpiece. The energy source used to fuse the material is for example a laser beam or an electron beam. This method makes it possible to form parts of great geometric complexity, impossible to achieve by techniques such as machining or molding. Additive manufacturing technology is used in aeronautics for the production of honeycomb structures. The embodiment of turbine blades by additive manufacturing is described, for example, in WO2013 / 124314. However, a closed cell structure is relatively complex to achieve in additive manufacturing, particularly for large cavities. In addition, certain applications specific to propeller blades require the coating of the internal walls of the cavities and / or the filling of cavities with a specific charge. The object of the present invention is to propose a method of manufacturing a hollow propeller blade, which is simple to produce and allows a variety of shape, filling and arrangement of the cavities of the blade. For this purpose, the object of the invention is a process of the aforementioned type, comprising the following steps: assembling said deposited material with an insert substantially disposed in a plane perpendicular to the axis, in contact with one end of the internal cavity , or at least one of the internal cavities, so as to close said internal cavity; then second deposition of material in successive layers along the axis, so as to define a section of the outer envelope and to completely coat the insert with the deposited material.
    [0002] According to other advantageous aspects of the invention, the method comprises one or more of the following characteristics, taken separately or according to all the possible technical combinations: the method further comprises a step of filling by a charge of the internal cavity or at least one of the internal cavities, said step being interposed between the first deposition of material and the assembly of said material with the insert; the filling step takes place according to the following phases: partial filling of the internal cavity by the load; then positioning the insert in contact with the end of the internal cavity, the insert having an orifice on the internal cavity; then complete filling of the internal cavity by the load, said load being introduced through the orifice of the insert; then obstruction of the orifice of the insert by a plug; - The method further comprises a step of forming a housing in the deposited material, said step taking place before the assembly of the deposited material and the insert, said housing being adapted to receive said insert during said assembly; - The insert has a flat surface opposite to the internal cavity closed by said insert; and the housing is configured so that, at the end of the assembly step, said planar surface of the insert is substantially coplanar with an end along the axis of the deposited material; the method then comprises a step according to which the support is dissociated from the body. The invention also relates to a propeller blade, capable of being derived from a manufacturing method as described above, said blade comprising a body arranged along an axis, said body comprising an outer envelope and a or a plurality of internal cavity (s) arranged along the axis, one end of the internal cavity, or at least one of the internal cavities, being closed by an insert substantially disposed in a plane perpendicular to the axis, the insert being attached to the body and fully embedded by the outer shell. According to other advantageous aspects of the invention, the blade comprises one or more of the following characteristics, taken separately or according to all the possible technical combinations: the filling load of the internal cavity is an electrorheological fluid, and the blade comprises at least two electrodes in contact with said electrorheological fluid, said electrodes being connected to a means for supplying electrical energy; the walls of the internal cavity are coated with an electrical insulator.
    [0003] The invention further relates to a helix comprising at least one blade as described above.
    [0004] The invention will be better understood on reading the description which follows, given solely by way of nonlimiting example and with reference to the drawings in which: FIG. 1 is a longitudinal sectional view of a blade according to a first embodiment of the invention; Figure 2 is a partial view, in longitudinal section, of the blade of Figure 1 during manufacture; Figure 3 is a longitudinal sectional view of a blade according to a second embodiment of the invention; Figure 4 is a partial view, in longitudinal section, of the blade of Figure 3. Figure 1 shows a blade 10 according to a first embodiment of the invention. Figures 3 and 4 show a blade 12 according to a second embodiment of the invention. In the following description, the elements common to the blades 10, 12 are designated by the same reference numbers. Each of the blades 10, 12 is intended to be part of a helix (not shown), comprising for example a plurality of identical blades. Each of the blades 10, 12 comprises a body 14 disposed along an axis 16 and of preferentially elongate shape. One end of the body 14 along the axis 16 is connected to a foot 18, 20. The foot 18, 20 is intended to be connected to the remainder of the propeller including the blade 10, 12. According to a first variant, shown in FIG. Figure 1, the body 14 and the foot 18 are formed of two different materials 22, 24. According to a second variant, shown in Figure 3, the body 14 and the foot 20 are formed of the same material 22. The materials 22 , 24 are, for example, metallic materials of the stainless steel type (austenitic or martensitic for example), copper alloys or titanium base alloys. The body 14 comprises an outer casing 26 which forms an outer surface 28 of the blade 10, 12. The body 14 further comprises one or more internal stiffeners 30. The outer casing 26 and the inner stiffener or 30 form the walls of the casing. One or more internal cavities 32. The cavities 32 preferably have an elongate shape, disposed along the axis 16, between the foot 18, 20 and a full 33 end portion of the body 14. One end of the cavities 32, on the side of the top portion 33 is formed by an insert 34, 36 fixed to the body 14. The insert 34, 36 has for example the shape of a flat plate and is substantially disposed in a plane perpendicular to the axis 16. A first face 38 of the insert 34, 36 forms an end wall of the cavities 32. A second opposite face 40 of the insert 34, 36 is in contact with the material 22 of the body 14, at the level of the summit portion 33. The body 14 and the insert 34, 36 are formed of two different materials 22, 42, said two materials being of a similar or different nature. The material 42 of the insert is for example a metallic material of the stainless steel type (austenitic or martensitic for example), cuprous alloy or titanium base alloy. As can be seen in FIGS. 1 and 3, the insert 34, 36 is entirely encapsulated by the material 22 of the body 14. In other words, the material 42 of the insert 34, 36 does not flush with the outer surface 28. In the examples of FIGS. 1 and 3, the same insert 34, 36 closes all the cavities 32 of the body 14. According to one variant, the cavities 32 of the body 14 are closed by at least two distinct inserts, said inserts being coplanar or else offset according to the axis 16. According to a first variant, the insert 34, 36 is full. According to a second variant, the insert 34, 36 has through orifices 44, oriented parallel to the axis 16. Said orifices 44 are, for example, closed by plugs 46. Like the insert 34, 36, the plugs 46 are fully encapsulated by the material 22 of the body 14 and are not flush with the outer surface 28. Preferably, at least one of the cavities 32 of the body 14 is filled with a filler material 48, 50. According to a first variant as shown in Figure 1, at least one other cavity 32 is empty. According to a second variant as shown in FIG. 3, all the cavities 32 are filled with a filler material 50. According to a first variant, the filler material 48, 50 is identical for all the cavities 32 of the body 14. According to a second variant, two separate cavities 32 are filled with a different material 48, 50. The filler material 48, 50 is chosen from organic, inorganic, metallic or composite materials, in solid or fluid form. In the example of FIG. 1, the filler material 48 is a solid in the form of a powder. In the example of Figure 3, the filler material 50 is a fluid. In order to prevent fluid leakage at the insert 36, a seal 52 is disposed between the first face 38 of the insert 36 and the material 22 of the body 14. In the example of FIG. the filler material 50 is an electrorheological fluid, i.e. a suspension of conductive particles dispersed in an electrical insulating fluid. The application of an electric field to such a fluid makes it possible to modify the rheological properties.
    [0005] For this purpose, the blade 12 of FIG. 3 comprises means 54, 56 for applying an electric field to the fluid 50 filling at least one of the cavities 32. Said means comprise two electrodes 54, 56 in contact with the fluid 50 of a same cavity 32. A first electrode 54 is located at the insert 36. Preferably, the electrode 54 is inserted into a plug 44 which serves as an electrode support. A second electrode 56 is located at one end of the cavity 32 near the foot 20. Preferably, the electrode 56 is inserted into a tubular hole 57 formed in the foot 20. The electrodes 54, 56 are connected to a supply means in electrical energy. Said supply means comprises electrical wires 58, 60 extending towards the axis of rotation (not shown) of the helix. The wire 60 connected to the second electrode 56 passes for example through the tubular hole 57. The wire 58 connected to the first electrode 54 passes through a channel 62, extending along the axis 16 and formed in a stiffener 30. As visible in FIG. 4, the wire 58 also passes into a cavity 64 formed in the insert 36 to join the first electrode 54. Preferably, the fluid 50 is electrically isolated from the walls of the cavity 32 by means of an insulating layer 66, 68 respectively deposited on the body 14 and the insert 36. The insulating layer 66, 68 is for example an organic paint. A method of manufacturing blades 10 and 12 will now be described. First, a support 18, 70 is provided, a surface 72 of said support being substantially disposed perpendicularly to the axis 16. Said axis 16 is then merged with the vertical axis and the surface 72 is oriented upwards. In the example of Figure 1, the support is constituted by the foot 18. Said foot 18 is made of metal, for example by molding or wrought. In the example of Figure 3, the support 70 is shown in dotted lines. A first part of the body 14 is then produced according to the additive manufacturing technology by directed energy deposition. More precisely, on the surface 72 of the support 18, 70 is carried out a first step of stacking layer by layer of material 22 along the axis 16. Each layer 74 of material 22 (FIG. 2) is deposited on the support 18, 70 or on the previous layer 76, for example in the form of powder, wire or metal strip. From a CAD (computer-aided design) model, the deposited material 22 is fused locally, so as to reproduce a section of the body 14 corresponding to the position of said layer 74 along the axis 16. The melting of the material 22 is for example carried out by laser beam or electron beam.
    [0006] In the example of Figure 1, the respective materials 22, 24 of the body 14 and the foot 18 are chosen so that the melting of the first layer of material 22 leads to a weld with the surface 72, to secure the body 14 and the foot 18. In the example of Figure 3, the foot 20 and the channel 62 are made by additive manufacturing as described above. The first step of stacking material 22 is continued to an intermediate layer 78, intended to be substantially coplanar with the second face 40 of the insert 34, 36. At this stage, a cleanliness of the workpiece is preferentially performed. The material 22 deposited and not fused is notably removed from the inside of the cavity (s) 32. In the vicinity of the intermediate layer 78, the CAD model of the blade 10, 12 provides for the fitting of a housing 80, of shape complementary to that of the insert 34, 36. According to one variant, the CAD model of the blade 10, 12 does not take account of the housing 80 and said housing 80 is made by machining, following the first stacking step described herein. -above. In the example of FIG. 3, grooves 82 are provided in contact with the housing 80 for the insertion of the seam (s) 52. The shape of the grooves 82 is provided by the CAD model of the blade 12 or, in Alternatively, the grooves are machined at the same time as the housing 80.
    [0007] In the example of Figure 3, following the formation of the housing 80 and grooves 82 by additive manufacturing or machining, an insulating layer 66 is deposited on the walls of the cavities 32 and in the grooves 82. The layer 66 is by example made by spraying or pouring an organic paint on the walls of the cavities 32. In parallel, the insert 34, 36 is manufactured independently of the body 14. The insert 34, 36 is for example made by traditional methods, type wrought or foundry, possibly followed by machining. Alternatively, particularly in the example of Figures 3 and 4, the insert 36 and the cavities 64 are made by additive manufacturing, similarly to the step described above. In the example of FIGS. 3 and 4, the first face 38 of the insert 36 is covered with an insulating layer 68. Any filler materials 48, 50 are then introduced into the cavities 32 of the body 14. Preferably, the introduction is interrupted when an upper level of the materials 48, 50 reaches a certain distance from the housing 80. The insert 34, 36 is then positioned in the housing 80. In the example of Figure 3, the seam (s) 52 are simultaneously placed in the groove or grooves 82. Similarly, the wires 58 of the first electrode or electrodes 54 are simultaneously placed in the cavities 64 and in the channel 62. The introduction of the materials 48, 50 is then continued by the orifices 44 of the insert 34, 36. In the case of a material 48 in powder form, one or more compaction steps, particularly by vibration, are advantageously provided before completing the introduction. When the cavities 32 are completely filled with filler materials 48, 50, the orifices 44 are closed by plugs 46. FIG. 2 represents the blade 10 of FIG. 1 during manufacture, at the end of this closing step orifices 44.
    [0008] In the example of FIG. 3, a plug 46 carries a first electrode 54. Before inserting the plug 46 into the corresponding orifice 44, the first electrode 54 is connected to its electrical wire 58 already inserted into the cavities 64 and in the channel 62. According to an alternative to the examples of Figures 1 to 4, the insert 34, 36 is full, that is to say that it has no orifice 44. In the case of filling of a cavity 32 by a filler material 48, 50, the solid insert is put in place when the cavity 32 is fully filled. At the end of the step of filling the cavity or cavities 32 and the possible closure of the orifices 44, a second portion of the body 14 is made by additive manufacturing. Said second part of the body 14 corresponds to the summit part 33.
    [0009] More precisely, from the intermediate layer 78 is made a second step of stacking / melting successive layers of material 22, as described above. The insert 34, 36 and the plugs 46 are sealed and embedded in the material 22. Preferably, the material 42 of the insert 34, 36 is chosen so that the melting of the first layer of material 22, deposited on said insert, lead to a weld with the surface 40. Preferably, a thickness 84 of the insert 34, 36 along the axis 16 is chosen sufficiently large that the filler materials 48, 50 are not affected by the heat transmitted. by said insert during the fusion. The second stage of stacking / melting of successive layers of material 22 continues until complete realization of the summit part 33, therefore of the outer envelope 26 of the body 14. In the example of FIG. 3, the support 70 is then dissociated from the blade 12. The hole or holes 57 is / are then machined in the foot 20 and the second electrode or 56 is / are inserted into said holes.
    [0010] According to a variant, the holes 57 are provided in the CAD model of the body 14 and the second electrode or electrodes 56 is / are put in place before the step of filling with the filler material 50. The blade 10, 12 is then assembled to the rest of the propeller (not shown), at the foot 18, 20. In the example of Figure 3, the son 58, 60 are connected to a source of electrical energy. During the use of the propeller, maintenance and maintenance operations are sometimes necessary, for example at the loads 48, 50 or the electrical system including the electrodes 54, 56. According to one embodiment of the invention such operations include a step of scouring or drilling the body 14, so as to reach the part of the blade 10, 12 requiring intervention. The body 14 is then reconstituted by additive manufacturing, similarly to the manufacturing method described above. According to one variant, the summit portion 33 is cut in such a way as to give access to the insert 34, 36, which makes it possible in particular to intervene on the first electrodes 54 of the blade 12. The summit portion 33 is then reconstituted, preferably by additive manufacturing as described above. Alternatively, the summit portion is reconstituted from traditional arc or laser charging methods. The embodiments described above relate to blades 10, 12 made of materials 22, 24, 42 of metal type. Alternatively, the method described above is made with other materials suitable for additive manufacturing technology, for example thermoplastic polymers.
    权利要求:
    Claims (10)
    [0001]
    CLAIMS 1. A method for manufacturing a blade (10, 12) of a propeller, said blade comprising a body (14) disposed along an axis (16), said body comprising: - an outer casing (26), and - a or a plurality of internal cavity (s) (32) disposed along the axis, the method comprising a step of first depositing a material (22) in successive layers on a support (18, 70), said layers being stacked along the axis, so as to define a section of the outer envelope and walls (30) of the internal cavity (s) (s), the method being characterized in that it then comprises the following steps: - assembly of said deposited material (22) with an insert (34, 36) substantially disposed in a plane perpendicular to the axis, in contact with an end (80) of the internal cavity, or at least one one of the internal cavities, so as to close said internal cavity; then - second deposition of material (33) in successive layers along the axis, so as to define a section of the outer envelope and to completely embed the insert with the deposited material.
    [0002]
    2. A manufacturing method according to claim 1, further comprising a step of filling by a load (48, 50) of the internal cavity (32), or at least one of the internal cavities, said step being interposed between the first material deposit (22) and the assembly of said material with the insert (34, 36).
    [0003]
    3. A manufacturing method according to claim 2, wherein the filling step is carried out according to the following phases: partial filling of the internal cavity by the load; then - positioning the insert in contact with the end of the internal cavity, the insert having an orifice (44) facing the internal cavity; then - complete filling of the internal cavity by the load, said load being introduced through the orifice of the insert; then - obstruction of the orifice of the insert by a plug (46).
    [0004]
    4. A manufacturing method according to one of the preceding claims, further comprising a step of forming a housing (80) in the deposited material, said step taking place before the assembly of the deposited material and the insert ( 34, 36), said housing being adapted to receive said insert during said assembly.
    [0005]
    5. A manufacturing method according to claim 4, wherein: the insert comprises a flat surface (40) opposite to the internal cavity (32) closed by said insert; and - the housing (80) is configured so that, at the end of the assembly step, said planar surface of the insert is substantially coplanar with an end (78) along the axis of the deposited material.
    [0006]
    6. A manufacturing method according to one of the preceding claims, further comprising a step wherein the support (70) is dissociated from the body (14).
    [0007]
    7.- Blade (10, 12) of propeller, may be derived from a manufacturing method according to one of the preceding claims, said blade comprising a body (14) disposed along an axis (16), said body comprising: - an outer casing (26), and - one or more internal cavity (s) (32) arranged along the axis, one end (80) along the axis of the internal cavity, or at least one of the internal cavities, being closed by an insert (34, 36) substantially disposed in a plane perpendicular to the axis, the insert being fixed to the body and fully encapsulated by the outer casing.
    [0008]
    8. A propeller blade (12) according to claim 7 taken in combination with claim 2, wherein: - the filling load (50) of the inner cavity (32) is an electrorheological fluid; and the blade comprises at least two electrodes (54, 56) in contact with said electrorheological fluid, said electrodes being connected to means (58, 60) for supplying electrical energy.
    [0009]
    9. The propeller blade of claim 8, wherein the walls of the inner cavity are coated with an electrical insulator (66, 68).
    [0010]
    10. Propeller comprising a blade according to one of claims 7 to 9.
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    同族专利:
    公开号 | 公开日
    FR3027243B1|2019-01-25|
    引用文献:
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    US1398062A|1921-01-21|1921-11-22|Charles D Brooks|Centrifugal propeller|
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    WO2017220058A1|2016-06-21|2017-12-28|MTU Aero Engines AG|Method for producing at least one hybrid component having additively manufactured sub-regions|
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    法律状态:
    2015-10-22| PLFP| Fee payment|Year of fee payment: 2 |
    2016-04-22| PLSC| Search report ready|Effective date: 20160422 |
    2016-10-10| PLFP| Fee payment|Year of fee payment: 3 |
    2017-09-21| PLFP| Fee payment|Year of fee payment: 4 |
    2018-09-24| PLFP| Fee payment|Year of fee payment: 5 |
    2019-10-07| PLFP| Fee payment|Year of fee payment: 6 |
    2020-09-10| PLFP| Fee payment|Year of fee payment: 7 |
    2021-09-10| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1402334|2014-10-16|
    FR1402334A|FR3027243B1|2014-10-16|2014-10-16|PROCESS FOR THE ADDITIVE MANUFACTURE OF A HOLLOW PROPELLER BLADE|FR1402334A| FR3027243B1|2014-10-16|2014-10-16|PROCESS FOR THE ADDITIVE MANUFACTURE OF A HOLLOW PROPELLER BLADE|
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