• 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 profiled element made of composite material comprises: - the production of a fiber preform (300), said preform being impregnated with a resin, - the polymerization of the resin with a matrix so as to obtain a profiled element composite material comprising a fiber reinforcement densified by a matrix, and - the attachment of a metal reinforcement to the profiled element made of composite material, the metal reinforcement being fixed on the profiled element by riveting. The method further comprises, prior to polymerization of the resin, inserting spacers (10) between the fibers of the fiber preform (300) and removing the spacers after the polymerization of the resin. in order to form at least one passage between the fibers of the fibrous reinforcement of the composite material element.
    公开号:FR3059268A1
    申请号:FR1661524
    申请日:2016-11-25
    公开日:2018-06-01
    发明作者:Eric Lucien Chassignet
    申请人:Safran Aircraft Engines SAS；
    IPC主号:
    专利说明:

    059 268
    61524 ® FRENCH REPUBLIC
    NATIONAL INSTITUTE OF INDUSTRIAL PROPERTY © Publication number:
    (to be used only for reproduction orders)
    ©) National registration number
    COURBEVOIE
    ©) Int Cl 8 : B 29 C 70/68 (2017.01), B 29 C 70/24, 70/48, 65/60, F 01 D 5/28, 5/14
    A1 PATENT APPLICATION
    ©) Date of filing: 25.11.16. © Applicant (s): SAFRAN AIRCRAFT ENGINES (30) Priority: Simplified joint stock company - FR. ©) Inventor (s): CHASSIGNET ERIC LUCIEN. @) Date of public availability of the request: 01.06.18 Bulletin 18/22. (56) List of documents cited in the report preliminary research: Refer to end of present booklet (© References to other national documents ©) Holder (s): SAFRAN AIRCRAFT ENGINES Company related: by simplified actions. ©) Extension request (s): @) Agent (s): CABINET BEAU DE LOMENIE.
    METHOD FOR MANUFACTURING A PROFILE ELEMENT IN COMPOSITE MATERIAL WITH FIXING OF A METAL REINFORCEMENT BY RIVETING.
    FR 3 059 268 - A1 (brj A method of manufacturing a profiled element of composite material comprises:
    the production of a fibrous preform (300), said preform being impregnated with a resin,
    the polymerization of the resin with a matrix so as to obtain a profiled element of composite material comprising a fibrous reinforcement densified by a matrix, and
    - The fixing of a metal reinforcement on the profiled element in composite material, the metallic reinforcement being fixed on the profiled element by riveting.
    The method further includes, before polymerizing the resin, inserting spacers (10) between the fibers of the fiber preform (300) and removing the spacers after polymerizing the resin. so as to form at least one passage between the fibers of the fibrous reinforcement of the element made of composite material.
    Invention background
    The invention relates to profiled elements of a turbomachine, in particular blades, of composite material comprising a fibrous reinforcement densified by a matrix, the matrix being obtained by injection of a liquid composition containing a precursor of the matrix in a fibrous preform.
    One area targeted is that of gas turbine blades for aeronautical engines or industrial turbines and, more particularly but not exclusively, fan blades for aeronautical engines.
    The manufacturing of a profiled element of composite material comprises the following stages:
    a) production of a fibrous structure by three-dimensional or multilayer weaving,
    b) compacting and shaping of the fibrous structure,
    c) placing the fibrous preform thus obtained in an injection molding tool (RTM),
    d) injection of a liquid precursor composition of a matrix material such as a resin into the fibrous preform,
    e) transformation of the liquid composition into a matrix so as to obtain a profiled element of composite material comprising a fibrous reinforcement densified by a matrix.
    In the case for example of an aeronautical engine fan blade, it is necessary to fix a metal reinforcement on the leading edge of the blade in order to protect the blade from impacts with external elements (for example birds ). The metal reinforcement is fixed to the leading edge of the blade by gluing. Gluing the metal reinforcement to the leading edge can prove to be a delicate operation. The quality of the bonding determines the strength of the metal reinforcement on the blade.
    Another solution is to fix the metal reinforcement on the blade by means of rivets. In this case, the blade of composite material and the metal reinforcement are drilled in order to provide in them a passage for the fixing rivets. However, drilling the blade of composite material causes the fibers of the fiber reinforcement of the blade to be cut, which can affect the mechanical properties of the blade produced.
    Subject and summary of the invention
    The present invention therefore aims to provide a solution for reliably fixing a metal reinforcement on a profiled element of composite material, and without altering the mechanical properties of the composite material constituting the blade.
    To this end, the invention proposes in particular a method of manufacturing an element made of composite material comprising:
    the production of a fibrous preform, said preform being impregnated with a resin,
    the polymerization of the resin with a matrix so as to obtain a profiled element of composite material comprising a fibrous reinforcement densified by a matrix,
    - The fixing of a metal reinforcement on the profiled element of composite material, the metallic reinforcement being fixed on the profiled element by riveting, characterized in that it further comprises, before the polymerization of the resin, the insertion at least one spacer between the fibers of the fibrous preform and the withdrawal of the spacer after the polymerization of the resin so as to form at least one passage between the fibers of the fibrous reinforcement of the element composite material profile.
    A profiled element of composite material is thus obtained with passages for rivets without having to make holes in the element. The spacing elements being inserted between the fibers, these are not broken and the profiled element of the resulting composite material has good mechanical properties even in the areas comprising rivets.
    According to one embodiment of the invention, at least one template corresponding to the dimensions of a passage for the body of a rivet is inserted between the fibers of the fibrous preform, the template being removed or eliminated after the polymerization of the resin in order to form in the profiled element made of composite material a passage capable of receiving the body of a rivet.
    According to one aspect of this embodiment, each template is removed from the profiled element of composite material mechanically.
    According to another embodiment of the invention, before the polymerization of the resin, a fibrous texture intended to form the fibrous preform is placed in the mold cavity of a shaping tool, said cavity comprising at least one spike or point making it possible to form at least one passage between the threads of the fibrous texture, the fibrous preform being maintained in the molding cavity during the polymerization of the resin.
    According to a particular characteristic of the invention, the fibrous preform is obtained from a fibrous texture produced by three-dimensional or multilayer weaving, the preform then being impregnated with a resin.
    According to another particular characteristic of the invention, the fibrous preform is obtained from a fibrous texture produced by three-dimensional or multilayer weaving from threads impregnated with a resin.
    The profiled element made of composite material may in particular correspond to a turbomachine blade and more particularly to an aeronautical engine fan blade.
    Brief description of the drawings
    Other characteristics and advantages of the invention will emerge from the following description of particular embodiments of the invention, given by way of nonlimiting examples, with reference to the appended drawings, in which:
    FIG. 1 very schematically illustrates a three-dimensional woven fibrous blank intended for the production of a fibrous structure in accordance with an embodiment of the invention;
    Figure 2 is a schematic view of a fibrous structure obtained from the fibrous blank of Figure 1;
    Figure 3 is a schematic exploded perspective view showing a shaping tool and the placement of the fibrous structure of Figure 2 therein;
    Figure 4 is a schematic perspective view showing the placement of the shaping tool of Figure 3 in a compacting and forming tool and performing a compacting and forming operation to obtain a fiber preform;
    FIG. 5 is a schematic perspective view showing the placement of the shaping tool in an injection tool and carrying out an operation of injecting a liquid composition of matrix precursor into the fiber preform in order to obtain a blade of composite material;
    Figure 6 is a schematic perspective view of the turbomachine blade made of composite material obtained after the operation of Figure 5;
    Figure 7 is a schematic perspective view of the turbine engine blade made of composite material of Figure 6 after removal of the templates;
    Figures 8A and 8B are schematic perspective views showing the attachment of a metal reinforcement on the blade of Figure 7;
    Figure 9 is a schematic view of a fibrous structure according to another embodiment of the invention;
    Figure 10 is a schematic exploded perspective view showing a shaping tool according to another embodiment of the invention and the placement of the fibrous structure of Figure 9 inside thereof;
    FIGS. 11A and 11B are schematic views respectively in perspective and in axial section showing the placement of the shaping tool of FIG. 10 in an injection tool and the carrying out of an injection operation of a liquid composition matrix precursor in the fiber preform to obtain a blade of composite material;
    FIG. 12 is a schematic perspective view of the blade of a turbomachine made of composite material obtained after the operation of FIG. 11A;
    FIGS. 13A and 13B are schematic perspective views showing the fixing of a metal reinforcement on the blade of FIG. 12.
    Detailed description of embodiments
    The invention applies generally to the production of profiled elements made of composite material, in particular blades, the profiled elements being produced from a fibrous preform in which a liquid composition precursor of a material of matrix is injected then transformed so as to obtain a part comprising a fibrous reinforcement densified by a matrix, a metallic reinforcement being moreover fixed by riveting on the profiled element.
    A manufacturing process according to the invention is described in relation to the manufacturing of a turbomachine blade. The process for manufacturing a blade of composite material with metal reinforcement according to the invention begins with the production of a fibrous blank obtained by three-dimensional weaving or by multilayer weaving.
    By three-dimensional weaving or 3D weaving is meant here a mode of weaving by which at least some of the warp threads link weft threads on several weft layers such as for example interlock weaving. By interlock weaving is meant here a 3D weaving weave in which each layer of warp links several layers of wefts with all the threads of the same warp column having the same movement in the plane of the weave.
    By multilayer weaving, we mean here a 3D weaving with several weft layers whose basic weave of each layer is equivalent to a conventional 2D fabric weave, such as a weave of canvas, satin or twill type, but with certain points of the weave which link the weft layers together.
    The production of the fibrous structure by 3D or multilayer weaving makes it possible to obtain a connection between the layers, therefore to have good mechanical strength of the fibrous structure and of the piece of composite material obtained, in a single textile operation.
    It may be advantageous to favor obtaining, after densification, a surface condition free of significant irregularities, that is to say a good finish condition to avoid or limit finishing operations by machining or to avoid the formation of resin clusters in the case of resin matrix composites. To this end, in the case of a fibrous structure having an internal part, or heart, and an external part, or skin adjacent to an external surface of the fibrous structure, the skin is preferably produced by weaving with a weave of the type canvas, satin or twill to limit surface irregularities, satin-like weave also providing a smooth surface appearance.
    It is also possible to vary the three-dimensional weaving weave in the core part, for example by combining different interlock weaves, or an interlock weaving and a multilayer weaving weave, or even different multilayer weaving weaves. It is also possible to vary the weaving weave in skin along the outer surface.
    An exemplary embodiment of a fibrous structure according to the invention is now described. In this example, the weaving is carried out on a Jacquard type loom.
    FIG. 1 very schematically shows the weaving of a fibrous blank 100 from which a fibrous structure 200 can be extracted (FIG. 2) making it possible to obtain, after compacting and shaping, a fibrous reinforcement preform of a blade of aeronautical engine.
    The fibrous blank 100 is obtained by three-dimensional weaving, or 3D weaving, or by multilayer weaving produced in a known manner by means of a jacquard type loom on which a bundle of warp or strand wires 101 has been placed in a plurality of layers, the warp threads being linked by weft layers 102 also arranged in a plurality of layers, some weft layers comprising braids as explained below in detail. A detailed embodiment of a fibrous preform intended to form the fibrous reinforcement of a blade for an aeronautical engine from a 3D woven fibrous blank is in particular described in detail in the documents US 7 101 154, US 7 241 112 and WO 2010/061140.
    The fibrous blank 100 is woven in the form of a strip extending generally in a direction X corresponding to the longitudinal direction of the blade to be produced. In the fiber blank 100, the fiber structure 200 has a variable thickness determined as a function of the longitudinal thickness and of the profile of the blade of the blade to be produced. In its part intended to form a foot preform, the fibrous structure 200 has an additional thickness 203 determined as a function of the thickness of the foot of the blade to be produced. The fibrous structure 200 is extended by a part of decreasing thickness 204 intended to form the lechasse of the blade then by a part 205 intended to form the blade of the blade. The part 205 has in a direction perpendicular to the direction X a profile of variable thickness between its edge 205a intended to form the leading edge of the blade and its edge 205b intended to form the trailing edge of the blade to be produced. . The part 205 includes first and second faces 205c and 205d extending between the edges 205a and 205b (FIG. 2) and intended to form the lower face and the upper face, or vice versa, of the blade of the blade.
    The fibrous structure 200 is woven in a single piece and must have, after cutting the nonwoven threads of the blank 100, the almost definitive shape and dimensions of the blade (“net shape”). To this end, in the thickness variation parts of the fibrous structure, as in the decreasing thickness part 204, the reduction in thickness of the preform is obtained by gradually removing weft layers during weaving.
    Once the weaving of the fibrous structure 200 in the blank 100 is completed, the nonwoven threads are cut. The fibrous structure 200 illustrated in FIG. 2 is then obtained, a structure woven in one piece and comprising the templates 10.
    The next step consists in compacting and shaping the fibrous structure 200 to form a fibrous preform ready to be densified. To this end, the fibrous structure is placed in a shaping tool 50 (Figure 3). The tool 50 comprises a first shell 51 comprising at its center a first imprint 511 corresponding in part to the shape and dimensions of the blade to be produced, the imprint 511 being surrounded by a first contact plane 512. The first shell 51 further comprises an injection port 510 intended to allow the injection of a liquid matrix precursor composition into a fibrous preform. The tool 50 also includes a second shell 52 comprising at its center a second imprint 521 corresponding in part to the shape and dimensions of the blade to be produced, the second imprint 521 being surrounded by a second contact plane 522 intended to cooperate with the first contact plane 512 of the first shell 51. The second shell further comprises an evacuation port 520 intended to cooperate with a pumping system.
    The first and second shells can in particular be made of metallic material such as aluminum for example or of graphite.
    The fibrous structure 200 is firstly positioned in the imprint 511 of the first shell 51, the second shell 52 is then placed on the first shell 51 in order to close the shaping tool 50. Once the tool 50 is closed as illustrated in FIG. 4, the first and second shells are in a position called “assembly position”, that is to say a position in which the first and second impressions 511, 521 are placed opposite one on the other while the first and second contact planes 512 and 522 are also facing each other. In this configuration, the first and second impressions 511, 521 together define an internal volume 53 having the shape of the blade to be produced and in which the fibrous structure 200 is placed. In the example described here, the impression 511 is intended forming the lower surface side of the blade preform while the imprint 521 is intended to form the upper side of the blade preform.
    The tool 50 with the fibrous structure inside it is placed in a compacting and forming tool 60 (FIG. 4). The tool 60 comprises a lower part 61 on which the first shell 51 of the tool 50 rests and an upper part 62 placed on the second shell 52 of the tool 50. The compacting and forming tool 60 is subjected to the application of a compaction pressure PC applied for example by placing the tool 60 in a press (not shown in FIG. 4). The application of the pressure PC brings the first and second shells 51 and 52 closer together until the first and second contact planes 512 and 522 meet, which makes it possible both to compact the fibrous structure 200 according to a compaction rate determined in order to obtain a fiber rate also determined and to shape the fibrous structure according to the profile of the blade to be manufactured. A preform 300 is then obtained having the shape of the blade to be produced (FIG. 5). The preform 300 has a profile of variable thickness between its edge 305a intended to form the leading edge of the blade and its edge 305b intended to form the trailing edge of the blade to be produced. The preform 300 includes first and second faces 305c and 305d extending between the edges 305a and 305b and intended to form the lower surface and the upper surface, or vice versa, of the blade of the blade.
    According to one embodiment of the invention, one or more templates, here several templates 10, are inserted between the fibers of the fibrous preform 300 in an area present in the vicinity of the edge 305a intended to form the leading edge of the 'dawn. Each template crosses the preform in the direction of its thickness, that is to say, from the face 305c to the face 305d (Figure 5). Each template 10 is introduced into the fiber preform 300 so as to be inserted between the son or strands of warp and weft. This creates a passage reserve between the fibers which can be maintained until the end of the manufacture of the blade of composite material, namely after the densification of the fibrous preform as explained below. The passage or passages are furthermore thus reserved without breaking the fibers of the warp and weft threads.
    Each template 10 has dimensions similar to those of the body of the rivet intended to be introduced into the passage formed after elimination of the template.
    In FIG. 5, the tool 50 is placed between a lower part 71 and an upper part 72 of an injection tool 70. The lower part 71 and the upper part 72 of the tool 70 are equipped with heating means (not shown in Figure 5). Once the tool 70 is closed, the blade is then molded by impregnating the preform 300 with a thermosetting resin which is polymerized by heat treatment. The well known injection or transfer molding process known as RTM (Resin Transfer Molding) is used for this purpose. In accordance with the RTM process, a resin 530, for example a thermosetting resin, is injected via the injection port 510 of the first shell 51 into the internal space 53 defined between the two cavities 511 and 521 and occupied by the preform 300. The port 520 of the second shell 52 is connected to an evacuation pipe maintained under pressure (not shown in FIG. 5). This configuration allows the establishment of a pressure gradient between the lower part of the preform 300 where the resin is injected and the upper part of the preform located near the port 520. In this way, the resin 530 injected substantially at the level of the lower part of the preform will gradually permeate all of the preform by circulating therein to the discharge port 520 through which the surplus is discharged. Of course, the first and second shells 51 and 52 of the tool 50 can comprise respectively several injection ports and several discharge ports.
    The resin used can be, for example, an epoxy resin of temperature class 180 ° C (maximum temperature supported without loss of characteristics). Resins suitable for RTM processes 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 part must be subjected. Once the resin has been injected into all of the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
    After injection and polymerization, the blade is demolded. It can possibly undergo a post-curing cycle to improve its thermomechanical characteristics (increase in the glass transition temperature). In the end, the blade is cut to remove the excess resin and the chamfers are machined. No other machining is necessary since, the part being molded, it respects the required dimensions.
    As illustrated in FIG. 6, a blade 400 is obtained formed of a fibrous reinforcement densified by a matrix except at the level of the templates
    10. The templates 10 are then removed in order to open the passages for fixing a metal reinforcement to the blade made of composite material. The templates can in particular be removed mechanically, for example by machining. The templates are preferably made with a material which does not adhere to the resin or little after the polymerization. The templates can in particular be made of one of the following materials; metal, polytetrafluoroethylene and polyamide.
    Once the templates 10 have been eliminated, the blade made of composite material 400 has passages 20 extending in the thickness of the blade and emerging both on the lower surface 400a and on the upper surface 400b of the blade 400 as illustrated in Figure 8A. In the example described here, the blade made of composite material 400 is reinforced at its leading edge 402. For this purpose, the passages 20 have been formed in an area close to the leading edge 402 in order to allow the fixing by riveting of a profiled metal reinforcement 30 whose shape corresponds to the part of the blade on which it must be fixed (FIG. 8A). More specifically, the metal reinforcement 30 comprises first and second parts 31 and 32 intended respectively to be fixed to the lower and upper surfaces 400a and 400b of the blade. The first part 31 has orifices 310 whose position has been defined so as to coincide with the passages 20 on the lower side 400a of the blade 400. Likewise, the second part 32 has orifices 320 whose position has been defined by so as to coincide with the passages 20 on the upper side 400b of the blade 400. The metal reinforcement 30 is fixed by positioning the reinforcement on the blade so as to align the orifices 310 and 320 with the passages 20 and by introducing a rivet 40 in each passage 20 as illustrated in FIG. 8B. A blade made of composite material 400 is thus obtained comprising a metal reinforcement 30 fixed to the latter by riveting, no thread of the fibrous reinforcement of the blade having been broken at the level of the housings in which the rivets 40 are placed.
    We will now describe another embodiment of a blade made of composite material with fixing of a metal reinforcement which differs from that described above in that passages for the rivets are reserved in the fibrous texture during its shaping in a tool. More specifically, a fibrous structure 500 is first produced (FIG. 9) making it possible to obtain, after compacting and shaping, a fibrous reinforcement preform of an aeronautical engine blade. The fibrous structure is produced from a fibrous blank obtained by three-dimensional weaving (3D) or by multilayer weaving like the fibrous blank 100 described above.
    The fibrous structure 500 has a variable thickness with, in its part intended to form a foot preform, an excess thickness part 503 determined as a function of the thickness of the foot of the blade to be produced. The fibrous structure 500 is extended by a part of decreasing thickness 504 intended to form the lechasse of the dawn then by a part
    505 intended to form the blade of the dawn. The part 505 has in a direction perpendicular to the direction X a profile of variable thickness between its edge 505a intended to form the leading edge of the blade and its edge 505b intended to form the trailing edge of the blade to be produced. . The part 505 comprises first and second faces 505c and 505d extending between the edges 505a and 505b and intended to form the lower surface and the upper surface, or vice versa, of the blade of the blade. The fibrous structure 500 is woven in one piece.
    The next step consists in compacting and shaping the fibrous structure 500 to form a fibrous preform ready to be densified. To this end, the fibrous structure is placed in a shaping tool 150 (Figure 10). The tool 150 includes a first shell 151 comprising at its center a first imprint 1511 corresponding in part to the shape and dimensions of the blade to be produced, the imprint 1511 being surrounded by a first contact plane 1512. The first shell 151 further comprises an injection port 1510 intended to allow the injection of a liquid matrix precursor composition into a fibrous preform. The tool 150 also includes a second shell 152 comprising at its center a second imprint 1521 corresponding in part to the shape and dimensions of the blade to be produced, the second imprint 1521 being surrounded by a second contact plane 1522 intended to cooperate with the first contact plane 1512 of the first shell 151. The second shell further comprises a discharge port 1520 intended to cooperate with a pumping system.
    The first and second shells can in particular be made of metallic material such as aluminum for example or of graphite.
    In accordance with one embodiment of the invention, one or more pins or points, here several pins 154, are present on the first shell 151. More specifically, the imprint 1511 of the first shell 151 comprises several pins 154 extending vertically from the surface 1511a of the imprint 1511 in an area of the imprint close to that intended to form the leading edge of the blade. Each pin 154 comprises a body 1540 having dimensions similar to those of the body of the rivet intended to be introduced into the passage formed in the blade after polymerization. The body 1540 is preferably extended by a point 1541 forming the free end of each pin 154. The point 1541 makes it possible to facilitate the penetration of the pins 154 into the fibrous texture 500 when it is placed in the tool 150. L 'footprint 1521 of the second shell 152 has holes 1523 which are intended to cooperate with the pins 154 present on the surface of the footprint 1511 of the first shell 151 once the tool 150 closed. The orifices 1523 are intended to receive the points 1541 of the pins 154 as illustrated in FIG. 11B.
    The fibrous structure 500 is firstly positioned in the imprint 1511 of the first shell 151, the second shell 152 then being placed on the first shell 151 in order to close the shaping tool 150. Each pin 154 then passes through the part 505 in the direction of its thickness, that is to say, from the face 505c to the face 505d. This creates a passage reserve between the fibers which can be maintained until the end of the manufacture of the blade of composite material, namely after the densification of the fiber preform as explained below. The passage or passages are furthermore thus reserved without breaking the fibers of the warp and weft threads.
    Once the tool 150 is closed as illustrated in FIGS. 11A and 11B, the first and second shells are in a position called “assembly position”, that is to say a position in which the first and second indentations 1511 , 1521 are placed opposite one another while the first and second contact planes 1512 and 1522 are also opposite one another. In this configuration, the first and second indentations 1511, 1521 together define an internal volume 153 having the shape of the blade to be produced and in which the fibrous structure 500 is placed. The pins 154 are present throughout the thickness of the texture fibrous, thus reserving passages for rivets after polymerization.
    In the example described here, the imprint 1511 is intended to form the pressure side of the blade preform while the imprint 1521 is intended to form the pressure side of the blade preform.
    As described above for the fibrous texture 200, the tool 150 with the fibrous structure 500 inside of it is placed in a compacting and forming tool (not shown in FIGS. 11A and 11B) which is subjected to the application of a compaction pressure applied for example by placing the tool in a press. The application of the pressure brings the first and second shells closer together until the first and second contact planes meet, which makes it possible both to compact the fibrous structure according to a determined compaction rate in order to obtain a fiber level also determined and to shape the fibrous structure according to the profile of the blade to be manufactured. A preform 600 is then obtained having the shape of the blade to be produced.
    In FIGS. 11A and 11B, the tool 150 is placed between a lower part 171 and an upper part 172 of an injection tool 170. The lower part 171 and the upper part 172 of the tool 170 are equipped with means heating (not shown in Figures 11A and 11B). Once the tool 170 is closed, the blade is then molded by impregnating the preform 600 with a thermosetting resin which is polymerized by heat treatment. The well known injection or transfer molding process known as RTM (Resin Transfer Molding) is used for this purpose. In accordance with the RTM process, a resin 1530, for example a thermosetting resin, is injected via the injection port 1510 of the first shell 151 into the internal space 153 defined between the two cavities 1511 and 1521 and occupied by the preform 600. The port 1520 of the second shell 152 is connected to an evacuation pipe maintained under pressure (not shown in FIG. 11A). This configuration allows the establishment of a pressure gradient between the lower part of the preform 600 where the resin is injected and the upper part of the preform located near the port 1520. In this way, the resin 1530 injected substantially at the level from the lower part of the preform will gradually permeate all of the preform by circulating therein to the discharge port 1520 through which the surplus is discharged. Of course, the first and second shells 151 and 152 of the tool 150 may comprise respectively several injection ports and several discharge ports.
    The resin used can be, for example, an epoxy resin of temperature class 180 ° C (maximum temperature supported without loss of characteristics). Resins suitable for RTM processes 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 part must be subjected. Once the resin has been injected into all of the reinforcement, it is polymerized by heat treatment in accordance with the RTM process.
    After injection and polymerization, the blade is demolded. It can possibly undergo a post-curing cycle to improve its thermomechanical characteristics (increase in the glass transition temperature). In the end, the blade is cut to remove excess resin and the chamfers are machined. No other machining is necessary since, the part being molded, it respects the required dimensions.
    As illustrated in FIG. 12, a blade 700 is obtained formed of a fibrous reinforcement densified by a matrix, the blade of composite material 700 also having passages 120 corresponding to the location of the pins 154. The passages 120 s extend in the thickness of the blade and opening both on the lower surface 700a and on the upper surface 700b of the blade 700. In the example described here, the blade made of composite material 700 is reinforced at the level of its leading edge 702. For this purpose, the passages 120 have been formed in an area close to the leading edge 702 in order to allow the fixing by riveting of a profiled metal reinforcement 130 whose shape corresponds to the part of the 'dawn on which it must be fixed (Figure 13A). More specifically, the metal reinforcement 130 comprises first and second parts 131 and 132 intended respectively to be fixed to the lower and upper surfaces 700a and 700b of the blade. The first part 131 comprises orifices 1310 whose position has been defined by so as to coincide with the passages 120 on the lower side 700a of the blade 700. Likewise, the second part 132 has orifices 1320 whose position has been defined so as to coincide with the passages 120 on the upper side 700b of the blade 700. The metal reinforcement 130 is fixed by positioning the reinforcement on the blade so as to align the orifices 1310 and 1320 with the passages 120 and by introducing a rivet 140 in each passage 120 as illustrated in FIG. 13B. A blade of composite material 700 is thus obtained comprising a metal reinforcement 130 fixed to the latter by riveting, no thread of the fibrous reinforcement of the blade having been broken at the level of the housings in which the rivets 140 are placed.
    According to a variant implementation of the process of the invention, the fibrous preforms 300 and 600 described above are already impregnated with a resin before their introduction into the shaping tool, for example by weaving the fibrous textures 200 and 500 from pre5 yarns impregnated with resin or by impregnating with resin the fibrous textures 200 and 500 after weaving. In this case, it is not necessary to inject a resin into the shaping tool before the polymerization of the resin.
    The invention finds an application in the manufacture of profiled elements of a turbomachine such as blades and in particular fan blades of the aeronautical field.
    权利要求:
    Claims (8)
    [1" id="c-fr-0001]
    1. Method for manufacturing a profiled element made of composite material (400) comprising:
    the production of a fibrous preform (300), said preform being impregnated with a resin,
    - polymerizing the resin with a matrix so as to obtain a profiled element made of composite material (400) comprising a fibrous reinforcement densified by a matrix,
    fixing a metal reinforcement (30) to the profiled element made of composite material, the metallic reinforcement being fixed to the profiled element by riveting, characterized in that it also comprises, before the polymerization of the resin, inserting at least one spacer between the fibers of the fiber preform (300) and removing said at least one spacer after polymerization of the resin so as to form at least one passage (20) between the fibers of the fibrous reinforcement of the composite material element (400).
    [2" id="c-fr-0002]
    2. Method according to claim 1, in which at least one jig (10) corresponding to the dimensions of a passage for the body of a rivet (40) is inserted between the fibers of the fibrous preform (200), the jig (10) being removed or eliminated after the polymerization of the resin in order to form in the profiled element made of composite material (400) a passage (20) capable of receiving the body of a rivet (40).
    [3" id="c-fr-0003]
    3. Method according to claim 2, wherein each template is removed from the profiled element of composite material mechanically.
    [4" id="c-fr-0004]
    4. Method according to claim 1, in which, before the polymerization of the resin, a fibrous texture (500) intended to form the fibrous preform (600) is placed in the molding cavity (153) of a shaping tool, said cavity comprising at least one pin or point (154) making it possible to form at least one passage between the threads of the fibrous texture, the fibrous preform (600) obtained being maintained in the mold cavity during the polymerization of the resin.
    [5" id="c-fr-0005]
    5. Method according to any one of claims 1 to 4, in which the fibrous preform (300; 600) is obtained from a fibrous texture (200; 500) produced by three-dimensional weaving or
    5 multilayer, the preform then being impregnated with a resin.
    [6" id="c-fr-0006]
    6. Method according to any one of claims 1 to 4, in which the fibrous preform (300; 600) is obtained from a fibrous texture (200; 500) produced by three-dimensional weaving or
    10 multilayer from son impregnated with a resin.
    [7" id="c-fr-0007]
    7. Method according to any one of claims 1 to 6, wherein the profiled element corresponds to a turbomachine blade.
    15
    [0008]
    8. The method of claim 7, wherein the turbomachine blade is an aeronautical engine fan blade.
    1/9
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    同族专利:
    公开号 | 公开日
    US10850456B2|2020-12-01|
    US20180147797A1|2018-05-31|
    FR3059268B1|2020-02-21|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20100133381A1|2007-04-24|2010-06-03|Airbus Operations Gmbh|Attachment arrangement for attaching a component to the fuselage of an aircraft,aircraft and method for constructing an attachment arrangement|
    WO2010061140A1|2008-11-28|2010-06-03|Snecma Propulsion Solide|Composite material turbine engine vane, and method for manufacturing same|
    DE102011054168A1|2011-10-04|2013-04-04|Rehau Ag + Co.|Tool for making a hole in a component|
    US5252279A|1991-01-17|1993-10-12|Reinhold Industries|Method for making perforated articles|
    US5246520A|1991-02-12|1993-09-21|Auto-Air Composites, Inc.|One step molded continuous fiber reinforced perforated composite panels|US10822969B2|2018-10-18|2020-11-03|Raytheon Technologies Corporation|Hybrid airfoil for gas turbine engines|
    US10774653B2|2018-12-11|2020-09-15|Raytheon Technologies Corporation|Composite gas turbine engine component with lattice structure|
    CN111016218B|2019-12-31|2021-08-17|北玻院复合材料有限公司|Preparation method of composite material lifting lug and composite material lifting lug|
    US11073030B1|2020-05-21|2021-07-27|Raytheon Technologies Corporation|Airfoil attachment for gas turbine engines|
    法律状态:
    2017-10-19| PLFP| Fee payment|Year of fee payment: 2 |
    2018-06-01| PLSC| Publication of the preliminary search report|Effective date: 20180601 |
    2018-10-24| PLFP| Fee payment|Year of fee payment: 3 |
    2019-10-22| PLFP| Fee payment|Year of fee payment: 4 |
    2020-10-21| PLFP| Fee payment|Year of fee payment: 5 |
    2021-10-20| PLFP| Fee payment|Year of fee payment: 6 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1661524|2016-11-25|
    FR1661524A|FR3059268B1|2016-11-25|2016-11-25|PROCESS FOR MANUFACTURING A PROFILE ELEMENT IN COMPOSITE MATERIAL WITH FIXING OF A METAL REINFORCEMENT BY RIVETING.|FR1661524A| FR3059268B1|2016-11-25|2016-11-25|PROCESS FOR MANUFACTURING A PROFILE ELEMENT IN COMPOSITE MATERIAL WITH FIXING OF A METAL REINFORCEMENT BY RIVETING.|
    US15/820,686| US10850456B2|2016-11-25|2017-11-22|Method of fabricating an airfoil element out of composite material and having metal reinforcement fastened by riveting|
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