• 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:
    A method of manufacturing a variable thickness composite material casing (100) for a gas turbine comprises: - three-dimensional weaving of a fibrous texture (140) in the form of a strip; the fibrous texture (140) in several superimposed layers (141, 142, 143, 144) on a mandrel (200) of profile corresponding to that of the casing to be manufactured, in order to obtain a fibrous preform (300) of shape corresponding to that of the casing to be manufactured, - the densification of the fibrous preform (300) by a matrix. When winding the fibrous texture (140) on the mandrel, an aerated material (150) is interposed between the adjacent turns of the fibrous texture, the aerated material (150) having a width less than the width of the fibrous texture (140) and defining a crankcase retention zone.
    公开号:FR3045456A1
    申请号:FR1563116
    申请日:2015-12-22
    公开日:2017-06-23
    发明作者:Yann Didier Simon Marchal；Bruno Jacques Gérard Dambrine
    申请人:Safran SA；SNECMA SAS；
    IPC主号:
    专利说明:

    BACKGROUND OF THE INVENTION The invention relates to gas turbine casings, and more particularly, but not exclusively, gas turbine fan casings for aeronautical engines.
    In a gas turbine engine, the fan housing performs several functions. It defines the air inlet duct in the engine, supports an abradable material facing the fan blade tips, supports a possible sound wave absorption structure for acoustic processing at the engine inlet and incorporates or support a retention shield. The retention shield is a debris trap holding debris, such as ingested objects or damaged blade fragments, projected by centrifugation to prevent them from passing through the crankcase and reaching other parts of the aircraft .
    Previously made of metallic material, the housings, such as the fan casing, are now made of composite material, that is to say from a fiber preform densified by an organic matrix, which makes it possible to produce parts having a lower overall mass than these same parts when they are made of metallic material while having a mechanical strength at least equivalent if not greater.
    The manufacture of a fan casing of organic matrix composite material is described in particular in document US Pat. No. 8,322,971. In the casing disclosed in document US Pat. No. 8,322,971, the retaining shield is constituted by a portion of extra thickness obtained at level of the fibrous reinforcement of the casing which has a progressive thickness. The fibrous reinforcement is obtained by winding a 3D woven fiber texture in which a gradual increase / decrease in thickness is obtained by varying the size of the yarns used and / or splitting the yarns in order to obtain thickness variations without to have out of the wires that must be cut afterwards.
    The formation of such a portion of extra thickness significantly increases the overall mass of the composite material housing.
    Object and summary of the invention
    It is therefore desirable to have a solution to have a composite material housing which comprises a retention zone while being simple and economical to manufacture and having a lower overall mass than the composite material housings of the prior art. For this purpose, according to the invention, there is provided a method of manufacturing a variable thickness composite material casing for a gas turbine, comprising: the realization by three-dimensional weaving of a fibrous texture in the form of a strip , the winding of the fibrous texture in several layers superimposed on a profile mandrel corresponding to that of the casing to be manufactured, in order to obtain a form of fiber preform corresponding to that of the casing to be manufactured, the densification of the fibrous preform by a matrix, characterized in that, during the winding of the fibrous texture on the mandrel, an aerated material is interposed between the adjacent turns of the fibrous texture, the aerated material having a width less than the width of the fibrous texture and delimiting a housing retention zone.
    By thus interposing an aerated material between the adjacent layers of the fibrous texture used to form the fibrous reinforcement of the casing, it is possible to form a portion of extra thickness in the casing adapted to form a retention zone or shield while minimizing the mass overall result of the crankcase with respect to a housing whose portion of extra thickness is made only with a fibrous texture having a variable thickness as in the prior art.
    The retention zone thus formed also reliably ensures its function, namely to retain debris, particles or objects ingested at the engine inlet, or from damage to the blades of the fan, and projected radially by rotation of the rotor. blower. Indeed, by alternating layers of shielding, formed here by the layers of the matrix-densified fibrous texture, with layers of aerated material, a ballistic principle is applied here according to which a plurality of relatively thin and spaced shielding layers is as powerful, if not more, than a single thick layer of armor. This principle is based on the fact that the first armor layer reached by a projectile divides the latter into a multitude of smaller, lower energy projectiles that will be easily stopped and held by the following armor layers. The aerated material may also participate to a lesser extent in attenuating the energy of small projectiles.
    The design of the casing according to the invention also makes it possible to obtain significantly thinner flanges than those obtained with the composite material casings of the prior art. Indeed, in the casings of the prior art, the thinning of the flanges is limited to meet the need for thickness in the extra thickness portion intended to form the retention zone.
    According to a particular characteristic of the process of the invention, the aerated material is made from a foam which is preferably capable of withstanding temperatures of about 200 ° C. and pressures of the order of 1 MPa.
    According to another particular characteristic of the process of the invention, the aerated material is made from a cellular structure which may be made in particular of aluminum or aramid.
    According to yet another particular characteristic of the method of the invention, after the winding step, the fibrous preform comprises n layers of fibrous texture corresponding to n turns of winding of said fibrous texture and n-1 layers of corresponding aerated material. at n-1 winding turns of said aerated material. The invention also proposes a gas turbine fan casing having a variable thickness and being made of a composite material with a fibrous reinforcement comprising a plurality of superimposed layers of a fibrous texture in the form of a band having a three-dimensional weave, said fibrous reinforcement being densified by a matrix, characterized in that an aerated material is interposed between two adjacent layers of the fibrous texture, the aerated material having a width less than the width of the fibrous texture and delimiting a retention zone of the housing.
    According to a particular characteristic of the housing of the invention, the aerated material is made from a foam which is preferably capable of withstanding temperatures of about 200 ° C and pressures of about 1 MPa.
    According to another particular characteristic of the casing according to the invention, the aerated material is made from a honeycomb structure which may be made in particular of aluminum or aramid.
    According to yet another particular characteristic of the casing according to the invention, the fibrous reinforcement comprises n layers of fibrous texture corresponding to n turns of winding of said fibrous texture and n-1 layers of aerated material corresponding to n-1 winding turns said aerated material. The subject of the invention is also an aeronautical gas turbine engine having a fan casing according to the invention.
    BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the invention will emerge from the following description of particular embodiments of the invention, given by way of non-limiting example, with reference to the appended drawings, in which: FIG. 1 is a perspective view in partial section of an aeronautical engine equipped with a composite material fan casing according to one embodiment of the invention, FIG. 2 is a sectional view along plane II-II of FIG. FIG. 3 is a schematic perspective view of a loom showing the weaving of a fibrous texture used for forming the fibrous reinforcement of the casing of FIGS. 1 and 2, FIG. in perspective showing the shaping of a fibrous texture and a band of ventilated material intended to form the reinforcement of the fan casing of FIGS. 1 and 2, FIG. 5 is a diagrammatic view showing the simultaneous winding of the fibrous structure and the aerated material web of FIG. 4, FIG. 6 is a sectional view showing the profile of the fibrous preform obtained after winding of the fibrous structure and of the aerated material web of FIGS. 4 and 5, FIG. 7 is a schematic view showing a tool for densifying the fibrous preform of FIG. 6 with a matrix.
    DETAILED DESCRIPTION OF EMBODIMENTS The invention will be described hereinafter in the context of its application to a gas turbine engine turbine engine fan casing.
    Such an engine, as shown very schematically in FIG. 1 comprises, from upstream to downstream in the direction of flow of gas flow, a fan 1 disposed at the engine inlet, a compressor 2, a combustion chamber 3, a high-pressure turbine 4 and a low-pressure turbine 5.
    The engine is housed inside a housing comprising several parts corresponding to different elements of the engine. Thus, the fan 1 is surrounded by a fan casing 100.
    FIG. 2 shows a fan casing profile 100 made of composite material as it can be obtained by a method according to the invention. The inner surface 101 of the casing defines the air inlet vein. It may be provided with an abradable coating layer 102 at the right of the trajectory of the blade tips of the fan, a blade 13 being partially shown very schematically. The abradable coating is thus disposed on only part of the length (in the axial direction) of the casing. An acoustic treatment coating (not shown) may also be disposed on the inner surface 101, in particular upstream of the abradable coating 102.
    The housing 100 may be provided with external flanges 104, 105 at its upstream and downstream ends to allow its mounting and its connection with other elements. Between its upstream and downstream ends, the housing 100 has a variable thickness, a thickening portion 110 of the housing having a greater thickness than the adjacent portions 120 and 130.
    The portion of extra thickness 110 extends on either side of the location of the fan, upstream and downstream, to form a retention zone or shield capable of holding debris, particles or objects ingested at the engine inlet, or from damage to the blades of the fan, and projected radially by rotation of the fan, to prevent them through the housing and damage other parts of the aircraft.
    The housing 100 is made of composite material with fiber reinforcement densified by a matrix. The reinforcement is made of fibers, for example carbon, glass, aramid or ceramic, and the matrix is made of polymer, for example epoxide, bismaleimide or polyimide, carbon or ceramic.
    The fibrous reinforcement is formed by winding on a mandrel a fibrous texture produced by three-dimensional weaving with evolutionary thickness, the mandrel having a profile corresponding to that of the casing to be produced. Advantageously, the fibrous reinforcement constitutes a complete tubular fibrous preform of the housing 100 formed in one piece with reinforcing portions corresponding to the flanges 104, 105.
    According to the invention, the fibrous reinforcement of the casing 100 consists of a plurality of superimposed layers 141 to 144 of a fibrous texture 140 in the form of a strip having a three-dimensional or multilayer weave, each layer 141 to 144 corresponding to a winding turn of the fibrous texture 140 (in FIG. 2 the layers 141 to 144 are densified by a matrix). In addition, an aerated material 150, here in the form of a web, is interposed between two adjacent layers of the fibrous texture, the web of aerated material 150 having an undersized width less than the width 140 of the fibrous texture 140 (FIG. ) and delimiting the retention zone of the casing 100. In the example described here, three layers 151 to 153 of aerated material 150 are interposed between the superposed layers 141 to 144 of the fibrous texture 140, each layer 151 to 153 corresponding to a winding tower of the band of aerated material 150. In general, for n superposed fibrous texture layers each corresponding to a winding turn of said fibrous texture, n-1 layers of aerated material each corresponding to a winding turn of said textile web.
    By thus interposing a layer of aerated material between the adjacent layers of the fibrous texture used to form the fibrous reinforcement of the casing, it is possible to form a portion of extra thickness in the casing adapted to form a retention zone or shield while minimizing the overall mass of the casing resulting with respect to a casing whose portion of extra thickness is made only with a fibrous texture having a variable thickness as in the document EP 1 961 923.
    The retention zone thus formed also reliably ensures its function, namely to retain debris, particles or objects ingested at the engine inlet, or from damage to the blades of the fan, and projected radially by rotation of the rotor. blower. Indeed, by alternating layers of shielding, formed here by the layers of the matrix-densified fibrous texture, with layers of aerated material, a ballistic principle is applied here according to which a plurality of relatively thin and spaced shielding layers is as powerful, if not more, than a single thick layer of armor. This principle is based on the fact that the first armor layer reached by a projectile divides the latter into a multitude of smaller, lower energy projectiles that will be easily stopped and held by the following armor layers. The aerated material may also participate to a lesser extent in attenuating the energy of small projectiles.
    The design of the casing according to the invention also makes it possible to obtain significantly thinner flanges than those obtained with the composite material casings of the prior art. Indeed, in the casings of the prior art, the thinning of the flanges is limited to meet the need for thickness in the extra thickness portion intended to form the retention zone.
    The aerated material may be in a variety of forms, such as a continuous web or a plurality of segments added end-to-end as winding progresses. It can also have various forms. It may in particular have, in width, a variable thickness profile for defining a thickening portion having a variable thickness in the width direction of the fibrous reinforcement.
    The aerated material may in particular be made from a foam or honeycomb-type honeycomb structure (Nida). In the example described here, the aerated material 150 is made of a foam tape.
    In the case of a foam, it preferably has a relatively low compression ratio so as not to crash too much during its winding with the fibrous texture and thus ensure the formation of the portion of extra thickness. The foam used is preferably able to withstand, that is to say, to preserve its integrity and its properties, in particular compressibility, at temperatures of about 200 ° C. and pressures of the order of 1 MPa which correspond to the conditions of manufacture of the composite material housing. By way of non-limiting example, a Rohacell® type foam, for example Rohacell® XT foam, may be used to form a web of aerated material to be interposed between adjacent layers of coiled fibrous texture. If the foam is rigid, it can be added in segments as the fibrous preform is rolled up, which is flexible.
    As indicated above, a honeycomb structure can also be used because it is easily rollable and has good compressive strength. The honeycomb structure may be in particular a honeycomb Nomex® from Hexcel®.
    A method of manufacturing the fan casing 100 is now explained.
    As shown in FIG. 3, a fibrous texture 140 is made in known manner by weaving by means of a jacquard loom 10 on which a bundle of warp yarns or strands 20 has been arranged in a plurality of layers, the warp threads being bound by threads or weft strands 30. The fibrous texture is produced by three-dimensional weaving. By "three-dimensional weaving" or "3D weaving" is meant here a weaving mode whereby at least some of the weft yarns bind warp yarns on several layers of warp yarns or vice versa. An example of three-dimensional weaving is so-called "interlock" weaving. By "interlock" weaving is meant here a weave weave in which each layer of warp yarn binds several layers of weft yarns with all the yarns of the same warp column having the same movement in the plane of the weave .
    As illustrated in FIGS. 3 and 4, the fibrous texture 140 has a strip shape that extends in length in a direction X corresponding to the direction of travel of the warp yarns or strands 20 and in width or transversely in a Y direction corresponding to the direction of the weft yarns or strands 30.
    The fibrous structure may in particular be woven from carbon fiber threads, ceramic such as silicon carbide, glass, or aramid.
    As illustrated in Figure 4, a fiber preform is formed by winding on a mandrel 200 of the fibrous texture 140 made by three-dimensional weaving, the mandrel having a profile corresponding to that of the housing to be produced. According to the invention, a band of aerated material 150 is wound with the fibrous texture 140, the band 150 being positioned above the first layer 141 of the texture 140 wound on the mandrel 200 so as to interpose a layer of material aerated 150 between two adjacent layers of fibrous texture corresponding to two turns of winding fibrous texture 140. The band 150 is positioned at a location on the fibrous texture 140 corresponding to the retention zone to be formed in the housing.
    Advantageously, the fibrous preform constitutes a complete tubular fibrous reinforcement of the casing 100 formed in one piece with a portion of extra thickness corresponding to the retention zone of the casing. For this purpose, the mandrel 200 has an outer surface 201 whose profile corresponds to the inner surface of the housing to be produced. By winding it on the mandrel 200, the fibrous texture 140 matches the profile of the latter. The mandrel 200 also comprises two flanges 220 and 230 for forming fiber preform portions corresponding to the flanges 104 and 105 of the casing 100.
    In forming the fibrous preform by winding, the fibrous texture 140 and the web of aerated material 150 are called from drums 60 and 70 respectively on which they are stored as illustrated in FIG. 5.
    FIG. 6 shows a sectional view of the fibrous preform 300 obtained after winding the fibrous texture 140 and the band of aerated material 150 in several layers on the mandrel 200. The number of layers or turns depends on the desired thickness and the thickness of the fibrous texture. It is preferably at least equal to 2. In the example described here, the preform 300 comprises four layers 141 to 144 of fibrous texture 140 and three layers 151 to 153 of aerated material strip 150 interposed respectively between the adjacent layers 141 and 142, 142 and 143, and 143 and 144.
    A fibrous preform 300 is obtained with a thickening portion 310 formed by the interposition of the layers 151 to 153 of the aerated material web 150 between the superposed layers 141 to 144 of the fibrous texture 140. The fibrous preform 300 also comprises end 320, 330 corresponding to the flanges 104, 105 of the housing.
    The fiber preform 300 is then densified by a matrix.
    The densification of the fiber preform consists in filling the porosity of the preform, in all or part of the volume thereof, with the constituent material of the matrix.
    The matrix can be obtained in a manner known per se according to the liquid method.
    The liquid process consists in impregnating the preform with a liquid composition containing an organic precursor of the matrix material. The organic precursor is usually in the form of a polymer, such as a resin, optionally diluted in a solvent. The fiber preform is placed in a sealable mold with a housing having the shape of the molded end piece. As illustrated in FIG. 7, the fiber preform 300 is here placed between a plurality of counter-mold sectors 240 and the support mandrel 200, these elements respectively having the outer shape and the inner shape of the casing to be produced. Then, the liquid matrix precursor, for example a resin, is injected throughout the housing to impregnate the entire fibrous portion of the preform. In this case, the aerated material is preferably impervious to the resin so as not to weigh down the final piece. In the case of a foam, it comprises closed cells or microbeads. In the case of a honeycomb structure, the walls of the structure are impermeable to the resin.
    The transformation of the precursor into an organic matrix, namely its polymerization, is carried out by heat treatment, generally by heating the mold, after removal of the optional solvent and crosslinking of the polymer, the preform being always maintained in the mold having a shape corresponding to that of the piece to realize. The organic matrix may in particular be obtained from epoxy resins, such as, for example, the high-performance epoxy resin sold, or liquid precursors of carbon or ceramic matrices.
    In the case of the formation of a carbon or ceramic matrix, the heat treatment consists in pyrolyzing the organic precursor to transform the organic matrix into a carbon or ceramic matrix according to the precursor used and the pyrolysis conditions. By way of example, liquid carbon precursors may be relatively high coke level resins, such as phenolic resins, whereas liquid precursors of ceramics, in particular of SiC, may be polycarbosilane type resins (PCS). or polytitanocarbosilane (PTCS) or polysilazane (PSZ). Several consecutive cycles, from impregnation to heat treatment, can be performed to achieve the desired degree of densification.
    According to one aspect of the invention, the densification of the fiber preform can be carried out by the well-known method of RTM ("Resin Transfer Molding") transfer molding. According to the RTM method, the fiber preform is placed in a mold having the shape of the casing to be produced. A thermosetting resin is injected into the internal space delimited between the mandrel 200 and the counter-molds 240. A pressure gradient is generally established in this internal space between the place where the resin is injected and the evacuation orifices of this last to control and optimize the impregnation of the preform by the resin.
    The resin used may be, for example, an epoxy resin. Suitable resins for RTM methods are well known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and / or the chemical nature of the resin is determined according to the thermomechanical stresses to which the piece must be subjected. Once the resin is injected into the entire reinforcement, it is polymerized by heat treatment in accordance with the RTM method.
    After injection and polymerization, the part is demolded. Finally, the piece is cut away to remove the excess resin and the chamfers are machined to obtain the housing 100 illustrated in Figures 1 and 2.
    权利要求:
    Claims (9)
    [1" id="c-fr-0001]
    A method of manufacturing a variable thickness composite material casing (100) for a gas turbine, comprising: - producing by three-dimensional weaving of a fibrous texture (140) in the form of a strip, - winding the fibrous texture (140) in several superimposed layers (141, 142, 143, 144) on a mandrel (200) of profile corresponding to that of the casing to be manufactured, in order to obtain a fiber preform (300) of corresponding shape to that of the casing to be manufactured, - the densification of the fibrous preform (300) by a matrix, characterized in that, during the winding of the fibrous texture (140) on the mandrel (200), an aerated material (150 ) is interposed between the adjacent turns of the fibrous texture, the aerated material (150) having a width less than the width of the fibrous texture (140) and delimiting a crush retention zone.
    [2" id="c-fr-0002]
    2. Method according to claim 1, characterized in that the aerated material (150) is made from a foam.
    [3" id="c-fr-0003]
    3. Method according to claim 1, characterized in that the aerated material is made from a honeycomb structure.
    [4" id="c-fr-0004]
    4. Method according to any one of claims 1 to 3, characterized in that, after the winding step, the fibrous preform comprises n layers of fibrous texture corresponding to n turns of winding said fibrous texture and n- 1 layer of aerated material corresponding to n-1 turns of winding said aerated material.
    [5" id="c-fr-0005]
    A gas turbine blower housing (100) having a variable thickness and being of a composite material with fibrous reinforcement comprising a plurality of superposed layers (141, 142, 143, 144) of a fibrous texture (140) under of a web having a three-dimensional weave, said fibrous reinforcement being densified by a matrix, characterized in that an aerated material (150) is interposed between two adjacent layers of the fibrous texture, the aerated material (150) having a width less than the width of the fibrous texture (140) and delimiting a crush retention zone.
    [6" id="c-fr-0006]
    6. Carter according to claim 5, characterized in that the aerated material (150) is made from a foam.
    [7" id="c-fr-0007]
    7. Carter according to claim 5, characterized in that the aerated material is made from a honeycomb structure.
    [8" id="c-fr-0008]
    8. Housing according to any one of claims 5 to 7, characterized in that the fibrous reinforcement comprises n layers of fibrous texture corresponding to n turns of winding of said fibrous texture and n-1 layers of aerated material corresponding to n- 1 turns of winding said aerated material.
    [9" id="c-fr-0009]
    An aeronautical gas turbine engine having a blower housing (100) according to any one of claims 5 to 6.
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    同族专利:
    公开号 | 公开日
    FR3045456B1|2020-10-23|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20060093847A1|2004-11-02|2006-05-04|United Technologies Corporation|Composite sandwich with improved ballistic toughness|
    US20090202763A1|2008-02-11|2009-08-13|Donald Rose|Multidirectionally Reinforced Shape Woven Preforms for Composite Structures|
    US20120099981A1|2010-10-22|2012-04-26|Snecma|Aeroengine fan casing made of composite material, and a method of fabricating it|EP3557007A1|2018-04-19|2019-10-23|United Technologies Corporation|Integrally built up composite fan case|
    FR3085299A1|2018-09-05|2020-03-06|Safran Aircraft Engines|HOUSING IN COMPOSITE MATERIAL WITH INTEGRATED STIFFENER|
    FR3092034A1|2019-01-30|2020-07-31|Safran Aircraft Engines|Composite material housing with local variation in thickness|
    法律状态:
    2016-12-09| PLFP| Fee payment|Year of fee payment: 2 |
    2017-06-23| PLSC| Publication of the preliminary search report|Effective date: 20170623 |
    2017-11-21| PLFP| Fee payment|Year of fee payment: 3 |
    2018-08-17| CD| Change of name or company name|Owner name: SAFRAN AIRCRAFT ENGINES, FR Effective date: 20180717 Owner name: SAFRAN, FR Effective date: 20180717 |
    2019-11-20| PLFP| Fee payment|Year of fee payment: 5 |
    2020-11-20| PLFP| Fee payment|Year of fee payment: 6 |
    2021-11-18| PLFP| Fee payment|Year of fee payment: 7 |
    优先权:
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    CN201680075858.1A| CN108430746B|2015-12-22|2016-12-21|Lightweight housing made of composite material and method for the production thereof|
    PCT/FR2016/053602| WO2017109403A1|2015-12-22|2016-12-21|Lighter-weight casing made of composite material and method of manufacturing same|
    US16/063,366| US11181011B2|2015-12-22|2016-12-21|Lighter-weight casing made of composite material and method of manufacturing same|
    EP16829413.0A| EP3393764A1|2015-12-22|2016-12-21|Lighter-weight casing made of composite material and method of manufacturing same|
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