CN115111060A - Aircraft engine air inlet duct and integrated forming process thereof - Google Patents
Aircraft engine air inlet duct and integrated forming process thereof Download PDFInfo
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- CN115111060A CN115111060A CN202210596529.9A CN202210596529A CN115111060A CN 115111060 A CN115111060 A CN 115111060A CN 202210596529 A CN202210596529 A CN 202210596529A CN 115111060 A CN115111060 A CN 115111060A
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/04—Air intakes for gas-turbine plants or jet-propulsion plants
- F02C7/042—Air intakes for gas-turbine plants or jet-propulsion plants having variable geometry
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/033—Deforming tubular bodies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/681—Component parts, details or accessories; Auxiliary operations
- B29C70/683—Pretreatment of the preformed part, e.g. insert
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/748—Machines or parts thereof not otherwise provided for
- B29L2031/749—Motors
- B29L2031/7492—Intake manifold
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Combustion & Propulsion (AREA)
- Physics & Mathematics (AREA)
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Abstract
The invention relates to an aircraft engine air inlet channel, in particular to an S-bend special-shaped air inlet channel integrally formed by metal-composite material-injection molding, which comprises hot air expansion S-bend special-shaped metal, a cured composite material and an injection molding reinforcing rib, wherein the hot air expansion S-bend special-shaped metal is formed by performing and heating air expansion on an integral metal pipe, the cured composite material is laid on the outer surface of the hot air expansion metal, and the injection molding reinforcing rib is arranged at the reinforcing rib on the outer surface of the cured composite material; the aircraft engine air inlet channel is manufactured by a hot gas expansion and co-curing integrated forming process. The invention also provides an integrated forming process of the aircraft engine air inlet. The invention integrates the metal thermal expansion technology, the composite material resin transfer molding technology and the injection molding technology to a high degree, so that the metal, the composite material and the plastic are solidified and integrated into a whole, and the comprehensive mechanical property of the air inlet channel is improved. Meanwhile, processing technology equipment is simplified, a unique integrated forming technology is formed, the production automation degree is improved, and the technology forming efficiency is high and the precision is good.
Description
Technical Field
The invention relates to an aircraft engine manufacturing technology in the technical field of aerospace, in particular to an aircraft engine air inlet channel and an integrated forming process thereof.
Background
The air inlet channel is a channel for providing large-flow air for an aircraft engine, ensures that an air inlet flow field meets the requirement of normal operation of an air compressor and a combustion chamber, is an important component of a propulsion system, and directly influences the maneuvering performance of the aircraft due to the advantages and disadvantages of the performance, so that the design and forming process technology of the air inlet channel has important significance.
Due to the limitation of the internal structure of the airplane and the performance requirements of the total pressure recovery coefficient and the distortion index, the air inlet channel is designed into an S-shaped curved special-shaped air inlet channel, namely the whole air inlet channel is S-shaped and the shapes of all the cross sections are different. Therefore, the air inlet duct is difficult to manufacture, and especially when the lightweight design of the airplane requires the air inlet duct to be integrally formed, the existing manufacturing process can not meet the requirements. Two typical prior art aircraft air scoop configurations are as follows:
1) metal block fabrication
Currently, the air inlet of the aircraft engine is mostly manufactured in blocks, and then a plurality of air inlet assemblies are welded or mechanically connected to form the air inlet, and the manufacturing process of each block assembly is obtained by removing materials through machining, as shown in fig. 5. The metal block manufacturing method has obvious defects, and particularly, after reinforcing ribs are added on the outer side of the air inlet, the metal cutting amount is very large, so that the processing efficiency is low, and the weight of the air inlet is heavy. Air inlet duct assemblies made of welded or mechanically connected air inlet duct assemblies are prone to connection failure or breakage under high frequency vibration and loads.
2) Manual laying of composite material and subsequent pasting and forming of composite material reinforcing rib structure
The composite material is a main means for improving the lightweight performance of the air inlet of the aircraft engine. However, the air inlet duct made of the composite material has great difficulty in the manufacturing process: 1. the inner cavity layering carbon fiber can not realize mechanization and automation and only depends on manual layering; 2. the carbon fiber is laid outside the core mold, and the core mold cannot be demoulded after being cured; 3. the reinforcing ribs on the outer side of the air inlet channel can only be adhered subsequently and cannot be integrally formed; 4. the air inlet channel is difficult to be mechanically connected because the carbon fiber curing structure is a brittle material in the installation process, and the connection position is easy to lose efficacy under the impact vibration load. In the service process of the composite material air inlet, the composite material air inlet is easy to age after being irradiated by the sun, frozen and blown by the wind and the rain.
The composite material thin-wall reinforcing rib structure is in a common main bearing structure form, has the structural advantages of a composite material laminated plate, and improves the stability and the bearing capacity of the whole structure by the reinforcing rib structure. Most of the forming processes of the composite materials at the present stage are manually laid for preforming, and then placed in an autoclave or an incubator for high-temperature curing forming. Because the aircraft engine has high requirements on the geometric accuracy of the composite material part, the forming accuracy of the composite material thin-wall reinforcing rib structure which is manually layered is difficult to ensure.
The invention is provided to solve the above problems.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an aircraft engine air inlet and an integrated forming process thereof, wherein the aircraft engine air inlet is of a multi-material mixed structure and is integrally formed by co-curing, and the whole aircraft engine air inlet adopts a metal-composite-injection multi-material mixed structure; the reinforcing rib structure adopts an injection molding curing process, so that the damage tolerance characteristic of the air inlet passage of the aircraft engine can be improved, the fatigue resistance can be improved, the viability and the competitiveness of the aircraft engine can be enhanced, and the requirements of high speed, long service life and safety of the aircraft can be met.
The invention provides an aircraft engine air inlet channel which is an S-bend special-shaped air inlet channel and comprises hot air inflation S-bend special-shaped metal, a cured composite material and an injection molding reinforcing rib, wherein the hot air inflation S-bend special-shaped metal is formed by performing and heating air inflation on an integral metal pipe, the cured composite material is laid on the outer surface of the hot air inflation metal, and the injection molding reinforcing rib is arranged at the reinforcing rib on the outer surface of the cured composite material; the aircraft engine air inlet channel is manufactured by a hot gas expansion and co-curing integrated forming process.
Further, the strengthening rib of moulding plastics includes a plurality of annular strengthening ribs that evenly set up along the intake duct outer peripheral face and a plurality of curve strengthening ribs that evenly set up along intake duct surface length direction, and every annular strengthening rib all has the tie point with every curve strengthening rib.
Optionally, the hot gas expansion metal is a titanium alloy, an aluminum alloy, a superalloy, or a steel.
Optionally, the reinforcement of the composite material is a wire or mesh of carbon fibers or glass fibers; the matrix of the composite material is thermoplastic or thermosetting resin or plastic.
Optionally, the injection moulded reinforcing bar material is a thermoplastic, thermosetting resin or plastic.
The invention provides an integrated forming process of an aircraft engine air inlet, which is a metal-composite material-injection hot air inflation and co-curing integrated forming process and comprises the following steps:
s1, bending a cylindrical hollow metal pipe into an S shape by using a preforming mold;
s2, laying a composite material reinforcement (such as wire rods and screen cloth) or a prepreg on the outer surface of the S-shaped metal pipe by using automatic wire laying or automatic belt laying equipment;
s3, placing the S-shaped metal pipe on which the composite material reinforcement or the prepreg is laid on a heating station, and heating the metal pipe to a temperature range with the best molding performance;
s4, heating the mold to a metal tube molding temperature range, moving the heated S-shaped metal tube into a molding mold, rapidly closing the mold, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a mold cavity shape, and obtaining an S-shaped bent special-shaped metal tube;
s5, adjusting the temperature of the forming die and the S-shaped bent special-shaped metal pipe to reach a temperature range suitable for curing the resin;
s6, if the composite reinforcement is a wire or a mesh, injecting matrix resin into the composite reinforcement by using an RTM or HP-RTM technology, and injecting the composite matrix resin through the glue injection port and the plastic reinforcement injection channel and the flow cavity of the forming mold, wherein the injection molding machine injects the reinforcement into the air inlet channel through the plastic reinforcement injection channel; if the laid composite material is prepreg, the injection molding machine injects the reinforcing ribs into an air inlet channel through the plastic reinforcing rib injection channel and the flow cavity;
s7, co-curing of thermosetting plastic, thermoplastic plastic or resin is achieved by means of a heating rod and a cooling water channel in the forming mold, and therefore the aircraft engine air inlet duct integrating a metal, composite material and injection molding mixture structure is obtained.
Further, in step S5, temperature adjustment of the molding die and the S-bend shaped metal tube is achieved by heating using a heating rod in the molding die, natural cooling, and cooling using a cooling water passage in the molding die.
Further, in step S6, a low viscosity matrix resin and a thermal plastic are injected from the injection opening and the injection opening of the molding die, respectively.
Optionally, the composite material matrix resin is injected by using an RTM or HP-RTM technology, air is exhausted in the mold filling process, and when the resin flows out from the glue overflow port, glue injection is stopped.
Further, in step S6, the injection molding technique is high-temperature high-pressure injection molding until the cavity of the reinforcing bar is filled with plastic.
Further, in step S7, circulating cooling water is introduced into the cooling water channel in the forming mold to cool the mold, thereby achieving solidification of the injection molded reinforcing rib.
Further, in step S7, after the composite material matrix and the injection molded stiffener are co-cured,
and opening the mold cavity, and taking out the S-shaped special aircraft engine air inlet formed by integrally forming the metal-composite-injection molding mixed structure.
The metal-composite-injection molding multi-material mixed structure integrated forming process has great technical advantages in the aspect of manufacturing of the aircraft engine air inlet; in the aspect of product performance, the air inlet passage assembly formed integrally adopts a closed inner cross section of the air inlet passage to replace a welding cross section, so that the rigidity and the fatigue strength of the air inlet passage are improved, the comprehensive mechanical property is higher, and the service performance is longer.
1. The aircraft engine air inlet channel integrally formed by the metal-composite-injection molding multi-material mixed structure has excellent comprehensive mechanical property, the mixed structure gives consideration to the toughness of a metal material and the high modulus of a composite material, and the metal-composite-injection molding integrally formed mixed structure has better advantages in the aspects of impact vibration resistance and energy absorption.
2. The metal-composite material-injection molding integrated forming process is a novel pioneering technology which integrates a hot air expansion technology, a composite material forming technology and an injection molding technology, grabs the characteristics and advantages of each technology, simplifies process equipment and forms a unique integrated forming process.
3. Compared with the traditional block combined air inlet, the weight of the metal-composite-injection molding integrated aircraft engine air inlet assembly can be reduced by more than 30%.
4. In the integrated forming process, the composite material reinforcement is laid on the outer surface of the metal pipe, so that automatic fiber laying, tape laying, winding and the like are very conveniently realized, and the production efficiency is improved.
5. The reinforcing ribs which are injected outside the air inlet channel can increase the rigidity of the whole assembly and are convenient to fix and mechanically connect.
6. The inner surface of the air inlet is formed by metal hot gas expansion, and after the air inlet is installed, the composite material is prevented from being directly blown by wind and exposed to the sun, so that the air inlet of the aircraft engine integrally formed by metal-composite material-injection molding has longer service performance in the aspects of corrosion resistance and aging resistance.
The integrated forming process of the aircraft engine air inlet with the metal-composite-injection molding multi-material mixed structure highly integrates a metal hot gas expansion technology, a composite material Resin Transfer Molding (RTM) or high-pressure resin transfer molding (HP-RTM) forming technology and an injection molding technology, so that the metal, the composite material and the plastic are co-cured and formed, the integrated forming of the aircraft engine air inlet is realized, the processing technology equipment is simplified, the production automation degree is improved, and the production efficiency is improved.
Drawings
FIG. 1 is a schematic structural diagram of an aircraft engine inlet according to an embodiment of the present invention.
Fig. 2 is a line drawing of the structure shown in fig. 1.
FIG. 3 is a flow chart of an integrated forming process of an aircraft engine inlet duct according to the present invention.
FIG. 4 is a schematic diagram of a preformed S-shaped metal tube used in the integrated forming process of the aircraft engine inlet according to the present invention.
FIG. 5 is a block diagram illustrating the components of a prior art aircraft engine inlet.
Wherein, the material comprises 10-hot-air expansion metal, 20-solidified composite material, 30-injection molding reinforcing rib, 31-annular reinforcing rib and 32-curve reinforcing rib.
Detailed Description
The present invention will be further described with reference to fig. 1-4.
As shown in fig. 1 and fig. 2, the aircraft engine air inlet of the present invention is an S-bend special-shaped air inlet, and includes a hot-air-bulging S-bend special-shaped metal 10, a cured composite material 20, and an injection-molded reinforcing rib 30, where the hot-air-bulging S-bend special-shaped metal 10 is formed by performing, heating and air-bulging on an integral metal pipe, the cured composite material 20 is laid on the outer surface of the hot-air-bulging metal 10, and the injection-molded reinforcing rib 30 is arranged at the reinforcing rib on the outer surface of the cured composite material 20; the aircraft engine air inlet channel is manufactured by a hot air inflation and co-curing integrated forming process.
The injection molding reinforcing rib 30 is a reinforcing rib formed by injection molding on the outer surface of the cured composite material 20, and comprises a plurality of annular reinforcing ribs 31 uniformly arranged along the outer peripheral surface of the air inlet and a plurality of curved reinforcing ribs 32 uniformly arranged along the length direction of the outer surface of the air inlet, and each annular reinforcing rib 31 and each curved reinforcing rib 32 are provided with connecting points.
The hot gas swell metal may be a titanium alloy, an aluminum alloy, a superalloy, or steel.
The reinforcement of the composite material is a wire or a mesh of carbon fiber or glass fiber; the matrix of the composite material is thermoplastic, thermosetting resin or plastic.
The material of the injection molding reinforcing rib is thermoplastic or thermosetting resin or plastic.
As shown in fig. 3, which is a flowchart of an integrated molding process of an aircraft engine inlet provided in the present invention, the integrated molding process of the aircraft engine inlet is a metal-composite material-injection hot gas expansion + co-curing integrated molding process, and includes the following steps:
s1, bending a cylindrical hollow metal pipe into an S shape by using a preforming mold;
s2, laying a composite material reinforcement (such as wire rods and screen cloth) or a prepreg on the outer surface of the S-shaped metal pipe by using automatic wire laying or automatic belt laying equipment;
s3, placing the S-shaped metal pipe paved with the composite material reinforcement or the prepreg on a heating station, and heating the metal pipe to a temperature range with the best molding performance (for example, the temperature of TC4 titanium alloy 704 ℃ and the temperature of 7075 aluminum alloy 240 ℃);
s4, heating the mold to a metal tube molding temperature range, moving the heated S-shaped metal tube into a molding mold, rapidly closing the mold, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a mold cavity shape, and obtaining an S-shaped bent special-shaped metal tube;
s5, adjusting the temperature of the forming die and the temperature of the S-shaped bent special-shaped metal pipe to reach a temperature range suitable for resin curing;
s6, if the composite reinforcement is a wire or a mesh, injecting matrix resin into the composite reinforcement by using an RTM (resin transfer molding) or HP-RTM (high pressure resin transfer molding) technology, and injecting the composite matrix resin through the glue injection port, the plastic reinforcing rib injection channel and the flow cavity of the forming mold, wherein the injection molding machine injects the reinforcing ribs into the air inlet channel through the plastic reinforcing rib injection channel while injecting the composite matrix resin through the glue injection port; if the laid composite material is prepreg, the injection molding machine injects the reinforcing ribs into an air inlet channel through the plastic reinforcing rib injection channel and the flow cavity;
s7, co-curing of thermosetting plastic, thermoplastic plastic or resin is achieved by means of a heating rod and a cooling water channel in the forming die, and therefore the aircraft engine air inlet channel integrating a metal, composite material and injection molding mixture structure is obtained.
In step S5, temperature adjustment of the forming die and the S-bend shaped metal tube is achieved by heating using a heating rod in the forming die, natural cooling, and cooling using a cooling water passage in the forming die.
In step S6, a low viscosity matrix resin and a thermal plastic are injected from the injection gate and the injection gate of the molding die, respectively.
And injecting the composite material matrix resin by using an RTM (resin transfer molding) or HP-RTM (high pressure-resin transfer molding) technology, exhausting air in the mold filling process, and stopping injecting the resin when the resin flows out of the glue overflow port.
In step S6, the injection molding technique is high-temperature high-pressure injection molding until the cavity of the stiffener is filled with plastic.
In step S7, circulating cooling water is introduced into the cooling water channel in the molding mold to cool the mold, thereby achieving solidification of the injection molded reinforcing rib.
In step S7, after the composite material matrix and the injection molding reinforcing rib are cured together, the mold cavity is opened, and the integrally formed S-bend special-shaped aircraft engine intake duct with the metal-composite material-injection molding mixed structure is taken out.
Example 1
A specific integrated molding process flow of the present invention is described below.
1. To facilitate the hot gas expansion of the metal tube, a pre-forming die is used to bend the cylindrical hollow metal tube into an S-shape, as shown in fig. 5.
2. And (3) automatically laying a composite material reinforcement, such as a wire rod, a mesh or a prepreg, on the outer surface of the S-shaped metal pipe by using automatic filament laying or automatic tape laying equipment.
3. The S-shaped metal pipe with the composite material reinforcement (or prepreg) laid is placed on a heating station, and the metal pipe is heated to a temperature range with the best molding performance by adopting electrode self-resistance heating.
4. And (3) heating the mould to the metal pipe forming temperature range (the temperature is the same as that in the step (3)) by using a heating rod in the forming mould, moving the heated S-shaped metal pipe into the forming mould and quickly closing the mould, sealing two ends of the S-shaped metal pipe, filling high-pressure gas, expanding the S-shaped metal pipe into a mould cavity shape (a special-shaped air inlet channel structure shape), and positioning a composite material reinforcement body (or prepreg) in a gap between a mould cavity and an expanded pipe.
5. Adjusting the temperature of the forming die and the S-shaped bent special-shaped metal pipe to reach the temperature range suitable for resin curing, wherein the means for adjusting the temperature comprises the following steps: 1) heating continuously by using a heating rod in the forming die, 2) naturally cooling, and 3) cooling by using a cooling water channel in the forming die and introducing circulating cold water for cooling.
6. If the composite material reinforcement is a wire or a mesh, injecting matrix resin into the composite material reinforcement by using an RTM (resin transfer molding) or HP-RTM (high pressure resin transfer molding) technology; if the laid composite material is a prepreg, the curing procedure is directly carried out.
7. The forming die is designed with a glue injection port, a plastic reinforcing rib injection channel and a flowing cavity, and the injection molding machine injects the reinforcing rib for the air inlet channel through the plastic reinforcing rib injection channel while injecting the composite material matrix resin through the glue injection port.
8. And respectively injecting low-viscosity matrix resin and thermoplastic from a glue injection port and an injection port of the mold. And injecting the composite material matrix resin by using an RTM (resin transfer molding) or HPRTM (high-performance resin transfer molding) technology, exhausting air in the mold filling process, and stopping injecting the resin when the resin flows out from the glue overflow port. The injection molding technology is high-temperature high-pressure injection molding until the reinforcing rib cavity is filled with the plastic. At this time, the forming mold is used as an inner cavity mold for injection curing and composite material curing, and the hot-air inflation formed metal tube is used as a core mold with the inflation pressure, and replaces devices such as a vacuum bag for composite material forming and the like.
9. The heating rod and the cooling water channel are arranged in the forming die, so that the forming die has a heating or cooling function, the co-curing requirement of thermosetting plastic, thermoplastic plastic or resin is met, and the integrated forming process of the hot air expansion metal, the composite material and the injection molding reinforcing rib is realized.
10. Circulating cooling water is introduced into a cooling water channel in the forming mold to cool the mold, so that solidification of the injection molding reinforcing rib is realized.
11. And after the composite material matrix and the injection-molded reinforcing rib are solidified together, opening the mold cavity, and taking out the S-bend special-shaped aircraft engine air inlet duct which is formed by the integrated molding process of the metal-composite-injection-molded multi-material mixed structure.
The invention has the beneficial effects that: aiming at the requirements of the aerospace field on strength, rigidity, service life, light weight and the like of materials, the aircraft engine air inlet with the metal-composite-injection molding multi-material structure is provided.
The metal-composite-injection molding aircraft engine air inlet channel integrated forming process is provided aiming at the comprehensive performance requirements of the aircraft engine air inlet channel such as impact resistance, fatigue resistance, corrosion and aging resistance and the like and the requirements of the automation degree and efficiency of the forming process.
Meanwhile, due to the RTM method, the energy consumption efficiency is improved, the working environment is improved, and the cost is reduced; the air pressure in the tube is kept all the time in the forming and curing processes, so that the adhesion strength of the fibers and the metal base material is improved; due to the adoption of the integrated co-curing molding process of metal, carbon fiber composite material and injection molding reinforcing ribs, the production efficiency is improved, and the quality of the material is improved.
While the invention has been described in connection with specific preferred embodiments thereof, it will be understood that the invention is not limited thereto, and that various modifications and substitutions can be made by those skilled in the art without departing from the spirit of the invention.
Claims (12)
1. The aircraft engine air inlet channel is characterized by being an S-bend special-shaped air inlet channel and comprising a hot air expansion S-bend special-shaped metal, a cured composite material and an injection molding reinforcing rib, wherein the hot air expansion S-bend special-shaped metal is formed by performing and heating air expansion on an integral metal pipe, the cured composite material is laid on the outer surface of the hot air expansion metal, and the injection molding reinforcing rib is arranged at the reinforcing rib on the outer surface of the cured composite material; the aircraft engine air inlet channel is manufactured by a hot gas expansion and co-curing integrated forming process.
2. An aircraft engine air inlet according to claim 1, wherein the injection molded ribs comprise a plurality of annular ribs disposed uniformly along the outer peripheral surface of the air inlet and a plurality of curved ribs disposed uniformly along the length of the outer peripheral surface of the air inlet, each annular rib having a connection point with each curved rib.
3. An aircraft engine air intake according to claim 1, wherein the auxetic metal is a titanium alloy, an aluminium alloy, a superalloy or a steel.
4. An aircraft engine air intake according to claim 1, wherein the reinforcement of the composite material is a wire or mesh of carbon or glass fibres; the matrix of the composite material is thermoplastic or thermosetting resin or plastic.
5. An aircraft engine air intake according to claim 1, wherein the injection moulded stiffener material is a thermoplastic, thermosetting resin or plastic.
6. An integrated forming process for an air inlet channel of an aircraft engine is a metal-composite material-injection hot gas expansion and co-curing integrated forming process, and is characterized by comprising the following steps of:
s1, bending a cylindrical hollow metal pipe into an S shape by using a preforming mold;
s2, laying a composite material reinforcement (such as wire rods and screen cloth) or a prepreg on the outer surface of the S-shaped metal pipe by using automatic wire laying or automatic belt laying equipment;
s3, placing the S-shaped metal pipe with the composite material reinforcement or the prepreg on a heating station, and heating the metal pipe to a temperature range with the best molding performance;
s4, heating the mold to a metal tube molding temperature range, moving the heated S-shaped metal tube into a molding mold, rapidly closing the mold, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a mold cavity shape, and obtaining an S-shaped bent special-shaped metal tube;
s5, adjusting the temperature of the forming die and the S-shaped bent special-shaped metal pipe to reach a temperature range suitable for curing the resin;
s6, if the composite reinforcement is a wire or a mesh, injecting matrix resin into the composite reinforcement by using an RTM or HP-RTM technology, and injecting the composite matrix resin through the glue injection port and the plastic reinforcement injection channel and the flow cavity of the forming mold, wherein the injection molding machine injects the reinforcement into the air inlet channel through the plastic reinforcement injection channel; if the laid composite material is prepreg, the injection molding machine injects the reinforcing ribs into an air inlet channel through the plastic reinforcing rib injection channel and the flow cavity;
s7, co-curing of thermosetting plastic, thermoplastic plastic or resin is achieved by means of a heating rod and a cooling water channel in the forming die, and therefore the aircraft engine air inlet channel integrating a metal, composite material and injection molding mixture structure is obtained.
7. An aircraft engine inlet duct integral molding process according to claim 6, wherein in step S5, the temperature adjustment of the molding die and the S-bend special-shaped metal pipe is realized by heating with a heating rod in the molding die, natural cooling and cooling with a cooling water channel in the molding die.
8. An aircraft engine inlet duct integral molding process according to claim 6, characterized in that in step S6, a low viscosity matrix resin and a hot plastic are injected from the injection inlet and the injection outlet of the molding die, respectively.
9. An aircraft engine air inlet duct integral molding process according to claim 6, characterized in that the composite material matrix resin is injected by using RTM or HP-RTM technology, air is exhausted during the mold filling process, and the injection is stopped when resin flows out from the glue overflow port.
10. An aircraft engine inlet duct integrated molding process as claimed in claim 6, wherein in step S6, the injection molding technique is high temperature and high pressure injection molding until the rib cavities are filled with plastic.
11. An aircraft engine inlet duct integral molding process as claimed in claim 6, wherein in step S7, the cooling water channel in the molding die is filled with circulating cooling water to cool the die, thereby realizing solidification of the injection molding reinforcing rib.
12. The integrated forming process of the aircraft engine air inlet duct as claimed in claim 6, wherein in step S7, after the composite material matrix and the injection-molded reinforcing ribs are co-cured, the mold cavity is opened, and the S-bend special-shaped aircraft engine air inlet duct integrally formed by the metal-composite-injection-molded mixed structure is taken out.
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Cited By (1)
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| WO2024188154A1 (en) * | 2023-03-13 | 2024-09-19 | 航宇智造（北京）工程技术有限公司 | Device unit for multi-element material hybrid forming by one-time mold opening and closing |
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| CN115111060B (en) | 2024-06-07 |
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