• 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 mold (100) for use in the manufacture of a gas turbine fan casing of composite material comprising: a mandrel (120) on which is wound a fiber preform (200) of fan casing and an annular wall (121) whose profile of the outer surface corresponds to that of the inner surface of the housing to be manufactured and two lateral flanges (122) whose profiles correspond to those of external flanges of the casing to be manufactured, a plurality of counter-mold angular sectors (130) sealingly assembled on the mandrel and for closing the mold and compacting a fibrous preform (200) wound on the mandrel, and a plurality of configured locking keys (140) to lock between them the neighboring counter-mold sectors. The invention also relates to a method of closing such a mold, and a method of manufacturing a fan casing.
    公开号:FR3044253A1
    申请号:FR1561396
    申请日:2015-11-26
    公开日:2017-06-02
    发明作者:Richard Mathon；Raoul Jaussaud；Dominique Michel Serge Magnaudeix
    申请人:SNECMA SAS；
    IPC主号:
    专利说明:

    Background of the invention
    The present invention relates to the general field of manufacture of gas turbine casings, and more particularly retention casings for a gas turbine engine fan for an aeronautical engine.
    In a gas turbine engine, a fan case performs several functions. It defines the air intake duct in the engine, supports an abradable material facing the top of the blades of the fan, supports a possible sound wave absorption structure for acoustic treatment at the engine inlet and incorporates or supports a retention shield. The latter is a trap holding debris, such as ingested objects or fragments of damaged blades, projected by centrifugation, to prevent them through the housing and reach other parts of the aircraft.
    The production of a fan casing made of composite material has already been proposed. For example, reference may be made to document EP 1,961,923, which describes the manufacture of a casing made of composite material having an evolutionary thickness comprising the formation of a fibrous preform by superposed layers of a fibrous texture and the densification of the fibrous reinforcement by a matrix. . More specifically, this document provides for the use of a mandrel for three-dimensional weaving of the fibrous texture, which is then wound in superposed layers on an impregnation mandrel having an outer surface whose profile corresponds to that of the central part of the casing to be manufactured and two side flanges corresponding to the fixing flanges of the casing. The fiber preform is held on the impregnation mandrel and resin impregnation is performed before polymerization.
    To impregnate the fiber preform by an RTM-type injection process, it is known to position the elements of a counter-mold on the impregnation mandrel and thus to form an injection mold. For example, reference may be made to WO 2013/060978 which discloses the implementation of angular sectors for closing the resin injection mold on the impregnation mandrel. However, closing the mold as provided in this document poses several problems. In particular, these angular sectors do not provide uniform compaction of the fiber preform, the applied pressure may vary from one sector to another and not being applied solely in the direction of the fiber preform. In addition, the seal between two adjacent angular sectors may not be satisfactory, which reduces the reliability of the mold during the injection of the resin.
    Therefore, a need exists to have an injection mold that does not have sealing problems during resin injection and that ensures uniform compaction of the fiber preform.
    Object and summary of the invention
    The main object of the present invention is thus to overcome such disadvantages by proposing a mold intended to be used for the manufacture of a gas turbine fan casing made of composite material comprising: a mandrel on which is intended to be wound a fibrous casing preform comprising an annular wall whose profile of the outer surface corresponds to that of the inner surface of the housing to be manufactured and two lateral flanges whose profiles correspond to those of external flanges of the casing to be manufactured, - a plurality of counter-mold angular sectors sealingly assembled on the mandrel and intended to close the mold and to compact a fibrous preform wound on the mandrel, and a plurality of locking keys configured to lock the counter sectors between them -molds neighbors.
    The mold according to the invention is remarkable in that it makes it possible, by means of the counter-mold angular sectors sealingly assembled on the mandrel, to compact the fibrous preform radially on the mandrel, while ensuring a good seal of the mold once closed. Indeed, the angular sectors against mold are assembled directly on the mandrel on the one hand, and locked together by locking keys on the other. The assembly of the sectors on the mandrel makes it possible to compact the fiber preform at a determined pressure, while also sealing between the sectors and the mandrel. The locking keys ensure the assembly of the angular sectors between them sealingly. Thus, the compaction and sealing functions between the sectors are dissociated, which increases the overall reliability of the mold.
    Preferably, the mold further comprises guide means for guiding each counter-mold sector when assembled on the mandrel of the mold. Such guiding means may comprise a plurality of fingers extending along a radial axis from a lateral flange of the mandrel, each finger cooperating with a groove present on each counter-mold sector.
    Also preferably, the mold further comprises a plurality of clamping screws extending along radial axes and configured to secure the counter-mold sectors to the mandrel of the mold.
    In an exemplary embodiment, the mold may comprise six annular sectors and six locking keys. The invention also relates to a method of closing an injection mold intended to be used for the manufacture of a gas turbine fan casing made of composite material, the mold comprising a mandrel on which is intended to be wound a fiberglass preform of the fan casing, the mandrel comprising an annular wall whose profile of the outer surface corresponds to that of the inner surface of the housing to be manufactured and two lateral flanges whose profiles correspond to those of external flanges of the housing to be manufactured, the mold further comprising a plurality of counter-mold angular sectors for closing the mold and compacting the fibrous preform wound on the mandrel, the method comprising: a) sealing the counter-mold sectors on the mold mandrel; and b) the assembly of locking keys between the adjacent sectors so as to ensure a tight locking of adjacent sectors to each other.
    When the counter-mold comprises at least three angular sectors, the assembly of the third angular sector between the first and the second sector already in place can be problematic. Indeed, the first and second angular sectors already assembled compact the fiber preform, while in the space in which the third sector will be assembled, the fiber preform is not yet compacted.
    When the third sector is assembled on the mandrel, it is brought in a radial direction. Therefore, a pinch of fibers may appear at the junction between the first and third sectors, and between the second and third sectors. Such nips are undesirable since they cause variations in the fiber content in the fiber preform, in particular by creating beadwork, and thus cause defects in the manufactured casing. For this purpose, the mold may comprise at least three back-mold sectors, step a) then comprising: sealing of a first and a second back-mold sector on the mandrel of the mold; leaving between them a space intended to accommodate a third counter-mold sector, - the temporary fixing of at least one compacting wedge on the mandrel in said space intended to accommodate the third counter-mold sector, the compaction wedge being positioned against a longitudinal face of the first or second counter-mold sector and being intended to compact a portion of the preform.
    Such compacting wedge compact a portion of the fiber preform located in the space that will accommodate the third angular sector at the ends of the first and second angular sectors. The transitions between the zones compacted by the first and second angular sectors, and the uncompacted zone, are displaced where the third angular sector will be positioned, and no longer at the interface between two angular sectors. Thus, pinching of the fibrous preform during assembly of the third sector is avoided.
    Advantageously, the compacting wedge comprises a face intended to compact the preform, the face having a profile configured to create a compacting transition zone between a portion of the preform compacted by a counter-mold sector and an uncompacted portion of the preform.
    In an exemplary embodiment, the face of the compacting wedge intended to compact the preform has a rounded profile at its end opposite to the longitudinal face of the against-mold sector against which the compacting box is positioned. Such a rounded profile makes it possible not to shear the preform when it is compacted by the compacting wedge. The invention also relates to a method of manufacturing a gas turbine fan casing of composite material comprising: winding a fibrous preform on the mandrel of a mold such as that described above, closing the mold by a method such as that described above, the injection into the mold of a resin, and the release of the fan casing.
    Finally, the invention also relates to a gas turbine comprising a fan casing manufactured by such a method.
    BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the present invention will emerge from the description given below, with reference to the accompanying drawings which illustrate an embodiment having no limiting character. In the figures: FIG. 1 is a diagrammatic view of a gas turbine fan casing, FIG. 2 is a perspective view of a mold according to the invention when it is closed, FIG. is a cross-sectional view of the mold of FIG. 2; FIG. 4 illustrates the guiding of an angular sector against the mold on the mandrel; FIG. 5 shows a compacting wedge assembled on the mandrel of the mold, and - Figures 6A and 6B are sectional views of the compacting wedge of Figure 5 assembled on the mandrel of the mold.
    DETAILED DESCRIPTION OF THE INVENTION The invention will be described below in the context of its application to the manufacture of a gas turbine engine airfoil fan casing.
    Figure 1 shows a perspective view of a blower housing 10 that can be manufactured using a mold and a method according to the invention. Such a housing is centered on a longitudinal axis XX and comprises an annular wall 11 delimited upstream by an upstream flange 12 and downstream by a downstream flange 3 (upstream and downstream being defined with respect to the flow of the gas stream in the gas turbine). The inner surface 14 of the annular wall 11 is intended to delimit the air inlet duct in the gas turbine.
    Figure 2 is a schematic perspective view of a mold according to the invention when closed.
    Such a mold can be used for the impregnation by a RTM ("Resin Transfer Molding") type process of a fibrous preform in order to manufacture a fan casing 10 such as that presented above. The fiber preform may be made by three-dimensional weaving of fibers, for example carbon, glass, aramid or ceramic, and the impregnating matrix may be of polymer, for example epoxide, bismaleimide or polyimimide.
    The mold 100 is rotatably mounted on a drive shaft (not shown) centered on the axis XX, and comprises a mandrel 120. Thereafter, the longitudinal, transverse and radial directions will be defined with respect to this axis XX , a transverse plane being a plane perpendicular to the longitudinal axis.
    The mandrel 120 comprises an annular wall 121 in the form of a drum on which is intended to be wound a fiber preform 200 (Figure 5), and two lateral flanges 122. The mandrel 120 is held on its drive shaft by the intermediate of six spokes 110.
    The flanges 122 form a support intended to receive the folded parts of the preform 200 wound on the mandrel 120, and which are intended to form the upstream and downstream flanges 13 of the fan casing 10.
    According to the invention, the mold 100 further comprises a counter-mold consisting of a plurality of counter-mold angular sectors 130 (here six in number) tightly assembled on the mandrel 120, and locked together in a sealed manner by as many lock keys 140.
    The sectors 130 are assembled on the side flanges 122 by clamping screws 131 which extend along a radial axis. These screws 131 allow the joining of the sectors 130 on the flanges 122 and the adjustment of the compaction pressure which is applied to the fiber preform 200. O-rings (not shown) positioned on the flanges 122 seal between the sectors 130 and the mandrel 120.
    Furthermore, the sectors 130 are locked together by locking keys 140. A key 140 is fixed between two adjacent sectors 130 by two rows of screws 141 extending longitudinally on the ends of each sector 130. The assembly of the keys locking 140 is made radially from the outside, once the sectors 130 assembled on the mandrel 120.
    In this way, the keys provide a circumferential clamping of the sectors 130 between them, and a seal between these sectors through flat seals (not shown) positioned between the sectors 130. Note that the keys 140 play no role in the assembly of the sectors 130 on the mandrel 120.
    The manufacture of a fan casing 10 will now be described in connection with FIGS. 3 to 6B.
    A fibrous preform 200 (FIG. 3) must first be wound on mandrel 120. Methods have already been proposed for winding a fibrous preform made, for example, by three-dimensional weaving around a mandrel such as that of the invention. and will not be described in more detail. For example, reference may be made to WO 2012/140355 which proposes a machine for winding a fibrous texture on an impregnation mandrel.
    Once the preform 200 is wound on the mandrel, the sectors 130 must be assembled on the mandrel 120.
    FIG. 4 shows a step of approaching a sector 130 on the mandrel 120. More particularly, guide means 123, 132 are provided to ensure that the sector 130 approaches the mandrel radially and comes to compact in a radial direction. the preform 200 on the mandrel 120. These guide means comprise fingers 123 extending along a radial axis provided on each flange 122, these fingers 123 being intended to cooperate with grooves 132 of complementary shape to that of the fingers 123 ' also extending along a radial axis and provided centered on the upstream and downstream faces of each sector 130.
    Once the sector 130 approached the mandrel and guided to it with the fingers 123 and grooves 132, the clamping screws 131 are positioned to finalize the tight assembly of the sector 130 on the mandrel. The compaction pressure of the preform 200 can be controlled and maintained by these clamping screws 131. The clamping screws 131 are preferably installed in a certain order, starting with the closest to the guide pin 123, and ending with those located at the ends of sector 130.
    With reference to FIG. 3, the assembly of the sectors 130 on the mandrel 120 takes place in a certain order: the sectors designated A, C and E are first positioned, then the sectors B, D and F. The sector A is positioned at the level of the winding end zone of the preform. It is important to mount the sectors in this order to avoid the formation of crumbs in the fiber preform 200 at the time of mold closure.
    According to an advantageous arrangement of the invention illustrated in FIG. 5, before setting up the last sectors B, D and F, two compacting wedges 300 (one only is represented in FIG. 5) are temporarily fixed on the mandrel 120. in the space that will be occupied by the sectors B, D and F. These wedges are mainly used to prevent the last three sectors B, D and F pinch the fiber preform at the interface between two sectors 130 at the time of assembly on the mandrel 120.
    For example, before assembling the sector B, a compacting wedge 300 (FIG. 5) is positioned temporarily against the longitudinal face 133 of the sector A, and another wedge 300 will be positioned against the longitudinal face 133 of the sector C (not shown in Figure 5). These shims 300 are fixed on the flanges 122 of the mandrel 120 by screws 301, and are intended to compact the preform 200 on an uncompacted portion thereof.
    As illustrated in FIG. 6A, which is a cross-sectional view of FIG. 5, each compaction wedge 300 is fed to the mandrel 120 along the face 133 of the neighboring sector 130, in the direction indicated by the arrow 302 (FIG. the difference of the sectors 130 which are brought radially on the mandrel 120). As a result, the nip of the fibrous preform 200 is avoided, and the transition between the compacted zone by the neighboring sector and the uncompacted zone is displaced.
    Figure 6B shows an enlarged view of Figure 6A at the base of compaction wedge 300.
    The compacting wedge 300 comprises a face 303 which compact the preform 200 and has a profile configured to create a compacting transition zone 201 between a portion 202 compacted by a sector 130 (here sector A) and an uncompacted portion 203 of the preform (corresponding to the location of sector B). Preferably, and in order to create a progressive transition zone 201 and not to shear the preform 200 with a sharp edge, the profile is rounded at the end of the spacer opposite the face 133 of the sector 130 against which the shim 300 is positioned. It will be understood that the preform 200 is compacted by shims 300 at the interface between sectors A and B, and B and C. The compaction transition zone 201 will be compacted by sector B when it is assembled on the mandrel 120, without generating pinching of the preform 200.
    The shims 300 must be held on the mandrel for a few minutes, and the last sectors B, D and F must be assembled quickly after removing the shims 300 so that the preform is still compacted at the wedges 300 and that any nipping is avoided .
    Once all the sectors 130 assembled, the locking keys 140 are placed between the neighboring sectors 130 to complete the closure of the mold.
    A polymerizable resin is then injected into the mold 100 by a pressure differential (by a process of the RTM type), and the latter is polymerized (for example by heating or cooling, depending on the nature of the resin used). The fan casing 10 thus manufactured can then be demolded.
    权利要求:
    Claims (11)
    [1" id="c-fr-0001]
    A mold (100) for use in the manufacture of a gas turbine blower housing (10) of composite material comprising: - a mandrel (120) on which is wound a fiber preform (200) fan case comprising an annular wall (121) whose profile of the outer surface corresponds to that of the inner surface (14) of the housing to be manufactured and two side plates (122) whose profiles correspond to those of external flanges (12). 13) of the housing to be manufactured; a plurality of counter-mold angular sectors (130) sealingly assembled on the mandrel and for closing the mold and compacting a fibrous preform (200) wound on the mandrel, and a plurality of locking keys (140) configured to lock the neighboring counter-mold sectors together in a sealed manner.
    [2" id="c-fr-0002]
    2. Mold according to claim 1, further comprising guiding means (123, 132) for guiding each counter-mold sector when assembled on the mandrel of the mold.
    [3" id="c-fr-0003]
    3. The mold of claim 2, wherein the guide means comprises a plurality of fingers (123) extending along a radial axis from a side flange (122) of the mandrel (120), each finger cooperating with a groove (132) present on each counter-mold sector.
    [4" id="c-fr-0004]
    The mold of any one of claims 1 to 3, further comprising a plurality of clamping screws (131) extending along radial axes and configured to secure the counter-mold sectors to the mandrel of the mold.
    [5" id="c-fr-0005]
    5. Mold according to any one of claims 1 to 4, comprising six annular sectors (130) and six locking keys (140).
    [6" id="c-fr-0006]
    A method of closing an injection mold (100) for use in the manufacture of a gas turbine blower housing (10) made of composite material, the mold comprising a mandrel (120) on which is for winding a fibrous pre-form (200) of the fan casing, the mandrel comprising an annular wall (121) whose profile of the outer surface corresponds to that of the inner surface (14) of the housing to be manufactured and two lateral flanges ( 122) whose profiles correspond to those of external flanges (11, 12) of the casing to be manufactured, the mold further comprising a plurality of counter-mold angular sectors (130) intended to close the mold and to compact the wound fiber preform on the mandrel, the method comprising: a) the sealing assembly of the counter-mold sectors on the mandrel of the mold, and b) the assembly of locking keys between the adjacent sectors so as to ensure a tight locking of the molds. neighborhoods between them.
    [7" id="c-fr-0007]
    The method of claim 6, wherein the mold comprises at least three counter-mold sectors, the step a) comprising: - sealing assembly of a first and a second counter-mold sector on the mandrel of the mold, leaving between them a space intended to accommodate a third counter-mold sector, - the temporary fixing of at least one compacting wedge (300) on the mandrel (120) in said space intended to accommodate the third sector counter-mold, the compacting wedge being positioned against a longitudinal face (133) of the first or second counter-mold sector and being intended to compact a portion (201) of the preform.
    [8" id="c-fr-0008]
    The method of claim 7, wherein the compaction shim (300) includes a face (303) for compacting the preform (200), the face having a profile configured to create a compaction transition zone (201). between a portion (202) of the compacted preform by a counter-mold sector and an uncompacted portion (203) of the preform.
    [9" id="c-fr-0009]
    9. The method of claim 8, wherein the face (303) of the compacting wedge intended to compact the preform has a rounded profile at its end opposite to the longitudinal face (133) of the against-mold sector ( 130) against which the compaction wedge is positioned.
    [10" id="c-fr-0010]
    A method of manufacturing a gas turbine blower housing of composite material comprising: - winding a fibrous preform (200) on the mandrel (120) of a mold (100) according to any one of claims 1 to 5, - closure of the mold by a method according to any one of claims 6 to 9, - the injection into the mold of a resin, and - the release of the fan casing (10).
    [11" id="c-fr-0011]
    A gas turbine engine comprising a fan casing (10) made by a process according to claim 10.
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    同族专利:
    公开号 | 公开日
    FR3044253B1|2018-05-18|
    CN108367462B|2020-12-04|
    CN108367462A|2018-08-03|
    US20180370082A1|2018-12-27|
    US10737407B2|2020-08-11|
    WO2017089680A1|2017-06-01|
    EP3380294A1|2018-10-03|
    EP3380294B1|2020-07-08|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    FR2957093A1|2010-03-02|2011-09-09|Snecma|FIBROUS PREFORM FOR A TURBINE RING SECTOR AND METHOD FOR MANUFACTURING SAME|
    WO2014131992A1|2013-03-01|2014-09-04|Safran|Injection mould for manufacturing a rotary part made of a composite material having external flanges, in particular of a gas turbine casing|
    US4288277A|1979-07-17|1981-09-08|Lembit Siilats|Molding system with retracting mold|
    US7335012B2|2004-12-22|2008-02-26|General Electric Company|Apparatus for fabricating reinforced composite materials|
    US7571527B2|2005-03-29|2009-08-11|The Boeing Company|Mandrel for fabrication of a monolithic composite nacelle panel|
    US7707708B2|2005-09-21|2010-05-04|Rohr, Inc.|Apparatus for making a tubular composite structure|
    CA2711929C|2008-01-31|2013-10-15|Alliant Techsystems Inc.|A stiffener tool positioning apparatus|
    US8025499B2|2008-11-03|2011-09-27|Rohr, Inc.|Multi-segment tool and method for composite formation|
    FR2974027B1|2011-04-13|2014-09-26|Snecma|COMPACTING DEVICE FOR MACHINE FOR WINDING A FIBROUS TEXTURE ON AN IMPREGNATION CHUCK|
    FR2981881B1|2011-10-26|2013-12-13|Snecma|DEVICE FOR MAINTAINING A FIBROUS TEXTURE ON AN IMPREGNATION CHUCK OF A WINDING MACHINE|
    FR2995555B1|2012-09-17|2017-11-24|Snecma|FIBROUS TEXTURE WINDING MACHINE FOR IMAGE ANALYSIS ALIGNMENT AND DECADING CONTROL|
    FR3026674B1|2014-10-07|2017-03-31|Snecma|METHOD FOR DISMANTLING ORGANIC MATRIX COMPOSITE MATERIAL|FR3100737B1|2019-09-12|2021-08-20|Safran Aircraft Engines|A method of closing an injection mold using sacrificial anti-pinch pleats|
    FR3100738B1|2019-09-12|2021-08-20|Safran Aircraft Engines|Method of closing an injection mold using anti-pinch strips|
    FR3108867A1|2020-04-07|2021-10-08|Safran Aircraft Engines|Mold for the manufacture of a turbine engine fan casing in composite material|
    WO2021205092A1|2020-04-10|2021-10-14|Safran Aircraft Engines|Mold for manufacturing a turbine engine fan casing from a composite material|
    WO2021245340A1|2020-06-04|2021-12-09|Safran Aircraft Engines|Rtm injection method and mould using symmetric anti-pinching sectors|
    法律状态:
    2016-11-09| PLFP| Fee payment|Year of fee payment: 2 |
    2017-06-02| PLSC| Search report ready|Effective date: 20170602 |
    2017-10-20| PLFP| Fee payment|Year of fee payment: 3 |
    2018-09-14| CD| Change of name or company name|Owner name: SAFRAN AIRCRAFT ENGINES, FR Effective date: 20180809 |
    2018-10-24| PLFP| Fee payment|Year of fee payment: 4 |
    2019-10-22| PLFP| Fee payment|Year of fee payment: 5 |
    2020-10-21| PLFP| Fee payment|Year of fee payment: 6 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1561396A|FR3044253B1|2015-11-26|2015-11-26|MOLD FOR THE MANUFACTURE OF A GAS TURBINE BLOWER CASING IN COMPOSITE MATERIAL AND METHOD FOR CLOSING SUCH MOLD|
    FR1561396|2015-11-26|FR1561396A| FR3044253B1|2015-11-26|2015-11-26|MOLD FOR THE MANUFACTURE OF A GAS TURBINE BLOWER CASING IN COMPOSITE MATERIAL AND METHOD FOR CLOSING SUCH MOLD|
    US15/777,713| US10737407B2|2015-11-26|2016-11-17|Mold for fabricating a turbine fan casing out of composite material, and a method of closing such a mold|
    PCT/FR2016/052987| WO2017089680A1|2015-11-26|2016-11-17|Mould for the manufacture of a gas turbine fan casing made of composite material and method for closing such a mould|
    EP16815580.2A| EP3380294B1|2015-11-26|2016-11-17|Mould for the manufacture of a gas turbine fan casing made of composite material and method for closing such a mould|
    CN201680068090.5A| CN108367462B|2015-11-26|2016-11-17|Mould for manufacturing a gas turbine fan casing made of composite material and method for closing the mould|
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