CN115111060B - Air inlet channel of aircraft engine and integrated forming process thereof - Google Patents
Air inlet channel of aircraft engine and integrated forming process thereof Download PDFInfo
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- CN115111060B CN115111060B CN202210596529.9A CN202210596529A CN115111060B CN 115111060 B CN115111060 B CN 115111060B CN 202210596529 A CN202210596529 A CN 202210596529A CN 115111060 B CN115111060 B CN 115111060B
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- inlet channel
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- 230000003014 reinforcing effect Effects 0.000 claims abstract description 69
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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
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Combustion & Propulsion (AREA)
- Physics & Mathematics (AREA)
- Composite Materials (AREA)
- Fluid Mechanics (AREA)
- Geometry (AREA)
- General Engineering & Computer Science (AREA)
Abstract
The invention relates to an air inlet channel of an aircraft engine, which is an S-bend special-shaped air inlet channel integrally formed by metal, composite material and injection molding, and comprises hot air expansion S-bend special-shaped metal, a solidified composite material and injection molding reinforcing ribs, wherein the hot air expansion S-bend special-shaped metal is formed by preforming an integral metal pipe and heating the integral metal pipe in an air expansion mode, the solidified composite material is paved on the outer surface of the hot air expansion metal, and the injection molding reinforcing ribs are arranged on the reinforcing ribs on the outer surface of the solidified composite material; the air inlet channel of the aircraft engine is manufactured by a thermal air expansion and co-curing integrated forming process. The invention also provides an integral forming process of the air inlet channel of the aircraft engine. The invention integrates the metal hot air expansion technology, the composite material resin transfer molding technology and the injection molding technology to ensure that the metal, the composite material and the plastic are co-cured into a whole, thereby improving the comprehensive mechanical property of the air inlet channel. Meanwhile, the 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 a manufacturing technology of an aircraft engine in the technical field of aerospace, in particular to an air inlet channel of the aircraft engine and an integrated forming process thereof.
Background
The air inlet channel is a channel for providing large-flow air for the aircraft engine, ensures that the air inlet flow field meets the requirements of normal operation of the air compressor and the combustion chamber, is an important component of the propulsion system, and the performance of the propulsion system directly influences the maneuvering performance of the aircraft, so that the design and the molding process technology of the air inlet channel have important significance.
Due to the limitation of the internal structure of the aircraft and the performance requirements of the total pressure recovery coefficient and the distortion index, the air inlet is designed into an S-bend special-shaped air inlet, namely the whole air inlet is S-shaped and the cross sections of the air inlet are different. Therefore, the manufacturing difficulty of the air inlet channel is high, and the existing manufacturing process can not meet the requirement especially when the air inlet channel is integrally formed in the light design requirement of the aircraft. Two typical aircraft inlet manufacturing methods in the prior art are as follows:
1) Metal block manufacturing
Currently, the air intake of an aircraft engine is mostly manufactured in blocks, and then a plurality of air intake assemblies are welded or mechanically connected, and the manufacturing process of each assembly is that of machining and removing materials, as shown in fig. 5. The metal block manufacturing mode has obvious defects, and particularly has large metal cutting amount after reinforcing ribs are added on the outer side of the air inlet channel, so that the processing efficiency is low and the weight of the air inlet channel is large. Welded or mechanically joined inlet assemblies are susceptible to joint failure or breakage under high frequency vibration and loading.
2) Subsequent pasting and forming of composite material manual laying and composite material reinforcing rib structure
The composite material is a main means for improving the light weight performance of the air inlet channel of the aircraft engine. However, the difficulty of the air inlet channel made of the composite material is high in the manufacturing process: 1. the carbon fiber laid in the inner cavity cannot be mechanized and automated and can only be laid manually; 2. carbon fiber is paved outside the core mold, and demolding cannot be performed after curing; 3. the reinforcing ribs on the outer side of the air inlet channel can be adhered only by the following steps and cannot be integrally formed; 4. in the installation process of the air inlet channel, the carbon fiber solidification structure is made of brittle materials, so that mechanical connection is difficult, and the connection position is easy to fail under impact vibration load. In the service process of the composite material air inlet, the composite material air inlet is easy to age after solar irradiation, icing and wind, rain and blowing.
The composite material thin-wall reinforcing rib structure is a common main bearing structure, has the structural advantage of the composite material laminated plate, and improves the stability and bearing capacity of the whole structure. The forming process of the composite material at the present stage is mainly to lay down the preform manually, and then place the preform in an autoclave or an incubator for high-temperature curing and forming. Because the aircraft engine has high requirements on the geometric precision of the composite material parts, the forming precision of the manually-paved composite material thin-wall reinforcing rib structure is difficult to ensure.
The present invention has been made in view of the above problems.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an air inlet of an aircraft engine and an integrated forming process thereof, wherein the air inlet of the aircraft engine is of a multi-material mixed structure and is co-cured and integrally formed, and the whole air inlet of the aircraft engine adopts a metal-composite material-injection molding multi-material mixed structure; the reinforcing rib structure adopts an injection molding curing process, so that the damage tolerance characteristic of the air inlet channel of the aircraft engine can be improved, the fatigue resistance performance is improved, the survivability and the competitiveness of the aircraft engine are enhanced, and the requirements of high speed, long service life and safety of an aviation aircraft are met.
The air inlet channel of the aircraft engine is an S-shaped special-shaped air inlet channel and comprises S-shaped special-shaped hot air expansion metal, a solidified composite material and injection molding reinforcing ribs, wherein the S-shaped special-shaped hot air expansion metal is formed by preforming and heating an integral metal pipe, the solidified composite material is paved on the outer surface of the hot air expansion metal, and the injection molding reinforcing ribs are arranged on the reinforcing ribs on the outer surface of the solidified composite material; the air inlet channel of the aircraft engine is manufactured by a thermal air expansion and co-curing integrated forming process.
Further, the injection molding reinforcing rib comprises a plurality of annular reinforcing ribs uniformly arranged along the outer circumferential surface of the air inlet channel and a plurality of curve reinforcing ribs uniformly arranged along the length direction of the outer surface of the air inlet channel, and each annular reinforcing rib is provided with a connecting point with each curve reinforcing rib.
Optionally, the hot gas expansion metal is titanium alloy, aluminum alloy, superalloy or 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, thermosetting resin or plastic.
Optionally, the injection molding reinforcing rib material is thermoplastic, thermosetting resin or plastic.
The invention provides an integrated forming process of an air inlet channel of an aircraft engine, which is an integrated forming process of metal-composite material-injection molding thermal expansion and co-curing, and comprises the following steps:
S1, bending a cylindrical hollow metal tube into an S shape by using a preformed die;
S2, using automatic wire laying or automatic tape laying equipment to lay a composite material reinforcement (such as wires and mesh) or prepreg on the outer surface of the S-shaped metal tube;
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 optimal molding performance;
s4, heating the die to a metal tube forming temperature range, then moving the heated S-shaped metal tube into a forming die and rapidly closing the dies, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a die cavity shape, and obtaining an S-bend special-shaped metal tube;
S5, adjusting the temperature of the forming die and the temperature of the S-bend special-shaped metal tube to enable the temperature to reach a temperature range suitable for resin curing;
S6, if the composite reinforcement is wire or 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 reinforcing ribs into an air inlet channel through a plastic reinforcing rib injection channel while injecting the composite matrix resin through a glue injection port by using a glue injection port of a molding die, wherein the plastic reinforcing rib injection channel is a plastic reinforcing rib injection cavity; if the composite material is laid to be prepreg, the injection molding machine injects the reinforcing ribs for the air inlet channel through the plastic reinforcing rib injection channel and the flowing cavity;
s7, co-curing of thermosetting plastics, thermoplastic plastics or resin is achieved by using a heating rod and a cooling water channel in the forming die, so that the air inlet channel of the aircraft engine integrating the metal, composite materials and injection molding mixture structure is obtained.
Further, in step S5, the temperature adjustment of the forming die and the S-bend shaped metal pipe is achieved by heating using a heating rod in the forming die, natural cooling, and cooling using a cooling water channel in the forming die.
Further, in step S6, a low-viscosity matrix resin and a thermoplastic are injected from the injection port and the injection port of the molding die, respectively.
Alternatively, RTM or HP-RTM technology is used to inject the matrix resin of the composite material, air is discharged in the mold filling process, and the injection is stopped when the resin flows out from the glue overflow port.
Further, in step S6, the injection molding technique is high temperature and high pressure injection molding until the plastic fills the cavity of the reinforcing rib.
Further, in step S7, the cooling water channel in the molding mold is filled with circulating cooling water to cool the mold, thereby realizing solidification of the injection molding reinforcing ribs.
Further, in step S7, after the composite matrix and the injection molding reinforcing ribs are cured together,
And opening the die cavity, and taking out the S-shaped special-shaped aircraft engine air inlet channel integrally formed by the metal-composite material-injection molding mixed structure.
The metal-composite material-injection molding multi-material mixed structure integrated forming process has great technical advantages in the aspect of manufacturing an air inlet channel of an aircraft engine; in terms of product performance, the integrally formed air inlet passage assembly adopts the closed inner section of the air inlet passage to replace a welded section, so that the rigidity and fatigue strength of the air inlet passage are improved, the integrated air inlet passage assembly has higher comprehensive mechanical properties and longer service performance.
1. The air inlet channel of the aircraft engine integrally formed by the metal-composite material-injection molding multi-material mixed structure has excellent comprehensive mechanical properties, the mixed structure takes the toughness of the metal material and the high modulus of the composite material into consideration, and the metal-composite material-injection molding integrated structure has better advantages in the aspects of shock vibration resistance and energy absorption.
2. The metal-composite material-injection molding integrated forming process is an innovative and novel technology which integrates the hot air expansion technology, the composite material forming technology and the injection molding technology, takes 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 material-injection integrated air inlet assembly of the aircraft engine can be reduced by more than 30%.
4. In the integrated forming process, the composite material reinforcement is paved on the outer surface of the metal pipe, so that automatic wire paving, tape paving, winding and the like are conveniently realized, and the production efficiency is improved.
5. The reinforcing ribs which are injection molded on the outer side of the air inlet channel can increase the rigidity of the whole assembly and facilitate fixation and mechanical connection.
6. The inner surface of the air inlet is formed by metal thermal expansion, and the composite material is prevented from being directly blown by wind and sun after being installed, so that the air inlet of the aircraft engine formed by metal-composite material-injection molding integrally has longer service performance in the aspects of corrosion resistance and ageing resistance.
The integrated forming process of the air inlet channel of the aircraft engine with the metal-composite material-injection molding multi-material mixed structure integrates the metal hot air expansion technology, the composite material Resin Transfer Molding (RTM) or the high-pressure resin transfer molding (HP-RTM) forming technology and the injection molding technology to ensure that the metal, the composite material and the plastic are co-cured and formed, so that the integrated forming of the air inlet channel of the aircraft engine is realized, the equipment of the processing technology is simplified, the degree of production automation is improved, and the production efficiency is improved.
Drawings
FIG. 1 is a schematic view of an embodiment of an aircraft engine intake according to 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 molding process of an air inlet channel of an aircraft engine.
Fig. 4 is a schematic view of a preformed S-shaped metal tube used in an integral molding process of an air inlet of an aircraft engine according to the present invention.
FIG. 5 is a schematic block diagram of a prior art assembly of an aircraft engine intake.
Wherein, 10-hot air expanded metal, 20-cured composite material, 30-injection molding reinforcing ribs, 31-annular reinforcing ribs and 32-curve reinforcing ribs.
Detailed Description
The air inlet passage of the aircraft engine and the integral forming process thereof are further described below with reference to fig. 1-4.
As shown in fig. 1 and 2, an air inlet of an aircraft engine is an S-bend special-shaped air inlet, and comprises an S-bend special-shaped hot air expanding metal 10, a cured composite material 20 and injection molding reinforcing ribs 30, wherein the S-bend special-shaped hot air expanding metal 10 is formed by preforming and heating an integral metal pipe, the cured composite material 20 is paved on the outer surface of the hot air expanding metal 10, and the injection molding reinforcing ribs 30 are arranged on the reinforcing ribs on the outer surface of the cured composite material 20; the air inlet channel of the aircraft engine is manufactured by a thermal air expansion 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 circumferential surface of the air inlet channel and a plurality of curve reinforcing ribs 32 uniformly arranged along the length direction of the outer surface of the air inlet channel, wherein each annular reinforcing rib 31 is connected with each curve reinforcing rib 32.
The hot gas expansion metal may be a titanium alloy, an aluminum alloy, a superalloy, or a steel.
The reinforcement of the composite material is wire or mesh cloth 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, thermosetting resin or plastic.
As shown in fig. 3, in order to provide a flowchart of an integrated forming process of an air inlet channel of an aircraft engine, the integrated forming process of the air inlet channel of the aircraft engine is a metal-composite material-injection molding thermal expansion and co-curing integrated forming process, and the method comprises the following steps:
S1, bending a cylindrical hollow metal tube into an S shape by using a preformed die;
S2, using automatic wire laying or automatic tape laying equipment to lay a composite material reinforcement (such as wires and mesh) or prepreg on the outer surface of the S-shaped metal tube;
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 optimal molding performance (for example, TC4 titanium alloy 704 ℃,7075 aluminum alloy 240 ℃);
s4, heating the die to a metal tube forming temperature range, then moving the heated S-shaped metal tube into a forming die and rapidly closing the dies, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a die cavity shape, and obtaining an S-bend special-shaped metal tube;
S5, adjusting the temperature of the forming die and the temperature of the S-bend special-shaped metal tube to enable the temperature to reach a temperature range suitable for resin curing;
S6, if the composite reinforcement is wire or 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 a glue injection port of a forming die, a plastic reinforcing rib injection channel and a flow cavity, wherein an injection molding machine injects reinforcing ribs for an air inlet channel through the plastic reinforcing rib injection channel; if the composite material is laid to be prepreg, the injection molding machine injects the reinforcing ribs for the air inlet channel through the plastic reinforcing rib injection channel and the flowing cavity;
s7, co-curing of thermosetting plastics, thermoplastic plastics or resin is achieved by using a heating rod and a cooling water channel in the forming die, so that the air inlet channel of the aircraft engine integrating the metal, composite materials and injection molding mixture structure is obtained.
In step S5, temperature adjustment of the forming die and the S-bend shaped metal pipe is achieved by heating using a heating rod in the forming die, natural cooling, and cooling using a cooling water channel in the forming die.
In step S6, a low-viscosity matrix resin and a thermoplastic are injected from the injection port and the injection port of the molding die, respectively.
And injecting composite matrix resin by using an RTM (resin transfer molding) or HP-RTM (high pressure-resin transfer molding) technology, discharging air in the mold filling process, and stopping injecting the resin when the resin flows out from the glue overflow port.
In step S6, the injection molding technique is high temperature and high pressure injection molding until the plastic fills the cavity of the reinforcing rib.
In step S7, circulating cooling water is introduced into a cooling water channel in the forming die to cool the die, so that solidification of the injection molding reinforcing ribs is realized.
In step S7, after the composite material matrix and the injection molding reinforcing ribs are cured together, opening a die cavity, and taking out the S-bend special-shaped aircraft engine air inlet channel integrally formed by the metal-composite material-injection molding mixed structure.
Example 1
The specific integrated molding process flow is described below.
1. To facilitate hot gas expansion of the metal tube, a preformed mold is used to bend the cylindrical hollow metal tube into an S-shape, as shown in fig. 5.
2. And automatically laying a composite material reinforcement, such as wires, mesh or prepreg, on the outer surface of the S-shaped metal tube by using automatic wire laying or automatic tape laying equipment.
3. And (3) placing the S-shaped metal pipe paved with the composite material reinforcement (or prepreg) on a heating station, and heating the metal pipe to a temperature range with optimal molding performance by adopting electrode self-resistance heating.
4. And heating the die to a metal tube forming temperature range (the same temperature as that of the step 3) by using a heating rod in the forming die, then moving the heated S-shaped metal tube into the forming die and rapidly closing the dies, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a die cavity shape (a special-shaped air inlet channel structural shape), and positioning a composite reinforcement (or prepreg) in a gap between a die cavity and the bulging pipe.
5. The temperature of the forming die and the S-bend special-shaped metal tube is regulated to reach a temperature range suitable for resin curing, and the means for regulating the temperature comprise: 1) continuously heating by using a heating rod in a forming die, 2) naturally cooling, 3) cooling by using a cooling water channel in the forming die and circulating cold water.
6. If the composite reinforcement is a wire or mesh, the matrix resin is injected into the composite reinforcement using RTM (resin transfer molding) or HP-RTM (high pressure resin transfer molding) techniques; if the laid composite material is prepreg, the curing procedure is directly entered.
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 reinforcing ribs for an air inlet channel through the plastic reinforcing rib injection channel while injecting composite matrix resin through the glue injection port.
8. And injecting low-viscosity matrix resin and thermoplastic respectively from the glue injection port and the injection port of the mold. And injecting composite matrix resin by using an RTM or HPRTM technology, discharging 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 plastic fills the cavity of the reinforcing rib. At this time, the molding die is used as an inner cavity die for injection molding curing and composite material curing, and the metal pipe formed by hot air inflation is used as a core die while maintaining inflation pressure, and replaces devices such as vacuum bags formed by composite materials.
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-solidification requirement of thermosetting plastics, thermoplastic plastics or resin is realized, and the integral forming process of the hot air expansion metal, the composite material and the injection molding reinforcing rib is realized.
10. And circulating cooling water is introduced into a cooling water channel in the forming die to cool the die, so that solidification of the injection molding reinforcing ribs is realized.
11. After the composite material matrix and the injection molding reinforcing ribs are solidified together, the mold cavity is opened, and the S-bend special-shaped aircraft engine air inlet channel of the metal-composite material-injection molding multi-material mixed structure integrated molding process is taken out.
The invention has the beneficial effects that: aiming at the requirements of the aerospace field on material strength, rigidity, service life, light weight and the like, the air inlet channel of the aircraft engine with the metal-composite material-injection molding multi-material structure is provided.
Aiming at the comprehensive performance requirements of the air inlet of the aircraft engine, such as impact resistance, fatigue resistance, corrosion resistance, aging resistance and the like, and the requirements of the automation degree, efficiency and the like of a forming process, the integrated forming process of the air inlet of the metal-composite material-injection aircraft engine is provided, and the forming process integrates the metal hot gas expansion technology, the composite material Resin Transfer Molding (RTM) or the high-pressure resin transfer molding (HP-RTM) forming technology and the injection molding technology to a high degree, so that the metal, the composite material and the plastic are co-cured and integrated, meanwhile, the processing process equipment is simplified, the production automation degree is improved, and the process forming efficiency is high and the precision is good.
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 pipe is always kept in the forming and curing processes, so that the adhesion strength of the fiber and the metal substrate is improved; because the metal, carbon fiber composite material and injection molding reinforcing rib integrated co-curing molding process is adopted, the production efficiency is improved, and the quality of the material is improved.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (12)
1. The air inlet channel of the aircraft engine is characterized by comprising an S-shaped special-shaped air inlet channel, an S-shaped special-shaped hot air expansion metal, a solidified composite material and injection molding reinforcing ribs, wherein the S-shaped special-shaped hot air expansion metal is formed by preforming and heating an integral metal pipe, the solidified composite material is paved on the outer surface of the hot air expansion metal, and the injection molding reinforcing ribs are arranged on the reinforcing ribs on the outer surface of the solidified composite material; the air inlet channel of the aircraft engine is manufactured by a thermal air expansion and co-curing integrated forming process.
2. The aircraft engine intake of claim 1, wherein the injection molded ribs include a plurality of annular ribs disposed uniformly along an outer peripheral surface of the intake and a plurality of curved ribs disposed uniformly along a length of an outer surface of the intake, each annular rib having a connection point with each curved rib.
3. The aircraft engine intake of claim 1, wherein the hot gas expansion metal is a titanium alloy, an aluminum alloy, a superalloy, or a steel material.
4. The aircraft engine intake of claim 1, wherein the reinforcement of the composite material is a wire or mesh of carbon or glass fibers; the matrix of the composite material is thermoplastic, thermosetting resin or plastic.
5. The aircraft engine intake of claim 1, wherein said injection molded bead material is a thermoplastic, thermoset resin or plastic.
6. An integrated forming process for an air inlet channel of an aircraft engine is a metal-composite material-injection molding thermal expansion and co-curing integrated forming process, and is characterized by comprising the following steps of:
S1, bending a cylindrical hollow metal tube into an S shape by using a preformed die;
S2, using automatic wire laying or automatic tape laying equipment to lay a composite material reinforcement or prepreg on the outer surface of the S-shaped metal pipe;
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 optimal molding performance;
s4, heating the die to a metal tube forming temperature range, then moving the heated S-shaped metal tube into a forming die and rapidly closing the dies, sealing two ends of the S-shaped metal tube, filling high-pressure gas, expanding the S-shaped metal tube into a die cavity shape, and obtaining an S-bend special-shaped metal tube;
S5, adjusting the temperature of the forming die and the temperature of the S-bend special-shaped metal tube to enable the temperature to reach a temperature range suitable for resin curing;
S6, if the composite reinforcement is wire or 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 reinforcing ribs into an air inlet channel through a plastic reinforcing rib injection channel while injecting the composite matrix resin through a glue injection port by using a glue injection port of a molding die, wherein the plastic reinforcing rib injection channel is a plastic reinforcing rib injection cavity; if the composite material is laid to be prepreg, the injection molding machine injects the reinforcing ribs for the air inlet channel through the plastic reinforcing rib injection channel and the flowing cavity;
s7, co-curing of thermosetting plastics, thermoplastic plastics or resin is achieved by using a heating rod and a cooling water channel in the forming die, so that the air inlet channel of the aircraft engine integrating the metal, composite materials and injection molding mixture structure is obtained.
7. The aircraft engine intake duct integrated molding process according to claim 6, wherein in step S5, temperature adjustment of the molding die and the S-bend profiled metal tube is achieved by heating using a heating rod in the molding die, natural cooling, and cooling using a cooling water channel in the molding die.
8. The aircraft engine intake duct integrated molding process according to claim 6, wherein in step S6, the low-viscosity matrix resin and the thermoplastic are injected from the injection port and the injection port of the molding die, respectively.
9. The integrated molding process of an aircraft engine intake duct of claim 6, wherein the injection of the composite matrix resin is performed using RTM or HP-RTM techniques, air is vented during the mold filling process, and the injection is stopped when resin flows out of the flash.
10. The integrated molding process of the air inlet channel of the aircraft engine according to claim 6, wherein in the step S6, the injection molding technology is high-temperature high-pressure injection molding until the plastic fills the reinforcing rib cavity.
11. The integrated molding process of the air inlet passage of the aircraft engine according to claim 6, wherein in step S7, the cooling water passage in the molding die is filled with circulating cooling water to cool the die, thereby realizing solidification of the injection molding reinforcing ribs.
12. The integrated molding process of the air inlet channel of the aircraft engine according to claim 6, wherein in the step S7, after the composite material matrix and the injection molding reinforcing ribs are cured together, the mold cavity is opened, and the air inlet channel of the S-bend shaped aircraft engine integrally molded by the metal-composite material-injection molding hybrid structure is taken out.
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| CN115111060A (en) | 2022-09-27 |
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