CN109016571B - Preparation method of airfoil - Google Patents
Preparation method of airfoil Download PDFInfo
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- CN109016571B CN109016571B CN201810756527.5A CN201810756527A CN109016571B CN 109016571 B CN109016571 B CN 109016571B CN 201810756527 A CN201810756527 A CN 201810756527A CN 109016571 B CN109016571 B CN 109016571B
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- 238000002360 preparation method Methods 0.000 title claims abstract description 16
- 239000006260 foam Substances 0.000 claims abstract description 186
- 239000004744 fabric Substances 0.000 claims abstract description 50
- 239000003292 glue Substances 0.000 claims abstract description 36
- 238000005520 cutting process Methods 0.000 claims abstract description 35
- 238000009966 trimming Methods 0.000 claims abstract description 7
- 238000000638 solvent extraction Methods 0.000 claims abstract description 4
- 230000009467 reduction Effects 0.000 claims description 52
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 40
- 239000000463 material Substances 0.000 claims description 28
- 238000010409 ironing Methods 0.000 claims description 21
- 229910052742 iron Inorganic materials 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 20
- 239000003795 chemical substances by application Substances 0.000 claims description 15
- 238000003892 spreading Methods 0.000 claims description 13
- 230000007480 spreading Effects 0.000 claims description 13
- 230000001681 protective effect Effects 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 10
- 238000002347 injection Methods 0.000 claims description 9
- 239000007924 injection Substances 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000007493 shaping process Methods 0.000 claims description 9
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 6
- 239000002313 adhesive film Substances 0.000 claims description 6
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000013461 design Methods 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 230000008569 process Effects 0.000 claims description 6
- 230000003247 decreasing effect Effects 0.000 claims description 5
- 239000000243 solution Substances 0.000 claims description 5
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 3
- 239000003822 epoxy resin Substances 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 229920000647 polyepoxide Polymers 0.000 claims description 3
- 239000003755 preservative agent Substances 0.000 claims description 3
- 230000002335 preservative effect Effects 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 238000005056 compaction Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 239000002131 composite material Substances 0.000 description 7
- 230000006872 improvement Effects 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
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Classifications
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- 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
-
- 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
-
- 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
- B29C70/682—Preformed parts characterised by their structure, e.g. form
-
- 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
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention discloses a preparation method of an airfoil in the technical field of aviation, which comprises the following steps of (1) preparing a mould; (2) cutting cloth; (3) combining the cloth; (4) preparing foam; (5) layering in a partitioning manner; (6) presetting; (7) layering of the lower joint area; (8) paving the skin; (9) layering an upper joint; (10) closing the mold; (11) injecting glue, curing, demoulding and trimming; the preparation cost of the invention is low.
Description
Technical Field
The invention belongs to the technical field of aviation, and particularly relates to a preparation method of an airfoil.
Background
The successful application of the composite material in the aerospace field has been only decades of history, but the composite material is increasingly widely applied in the aerospace field due to the advantages of specific strength, specific rigidity, designability, convenience for large-area integral forming and the like. At present, composite material structures have become four major structural materials in the aerospace field together with aluminum alloys, titanium alloys and alloy steels.
The composite material is successfully developed in the middle of the 60's of the 20 th century, and then is widely applied to aeronautical structures such as airplanes and the like. For decades, the application of composite materials in the field of aeronautics has gone through a development route from small to large, from secondary to primary, from local to overall, and from structure to function.
Meanwhile, the scientific technology is developed more and more rapidly, the composite material is developed more and more rapidly, and the wing surface prepared by the composite material in the prior art is large in mass and high in preparation cost.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to overcome the defects in the prior art, solve the technical problems of high preparation cost and large mass of the prepared airfoil in the prior art, and provide the preparation method of the airfoil.
The purpose of the invention is realized as follows: a method of making an airfoil comprising the steps of,
(1) preparation of a mold: cleaning residues in the inner cavity of the mold, wiping the inner cavity of the mold by using clean cloth tape soaked acetone after the residues are cleaned, cleaning residues affecting products, wiping the inner cavity of the mold by using the clean cloth tape soaked release agent after the residues are dried, wiping the release agent again after the release agent is dried, repeating the step of wiping the release agent for 5-8 times, and covering the mold with a preservative film for later use;
(2) fabric cutting: cutting the carbon fiber cloth into enough material for the product and reserving spare material according to the shape, quantity and angle requirements of the process file by using a cloth cutting machine, shaping the cut cloth by using a shaping agent after the cutting is finished, numbering by using a marking pen after the shaping, and placing the cloth in a specified area in sequence;
(3) cloth combination: sequentially closing two adjacent layers of cloth, ironing each combined layer by using an electric iron, continuously numbering, and putting the combined layers in sequence;
(4) preparation of the foam: processing front edge foam, main beam foam and rear edge foam according to design requirements, cutting the foam appearance by an art designer knife, and polishing by abrasive paper after cutting to ensure that the foam meets the design requirements;
(5) layering in a partitioning manner: paving the front edge foam, wherein paving areas of the front edge foam are an E area and an F area respectively, before paving, a layer of glue film is wrapped on the main beam foam, the glue films on the upper surface and the lower surface are completely adhered, then paving is carried out on the E area and the F area in sequence, the E area is a thickness reduction section of the front edge foam, and the F area is the whole front edge foam;
the paving areas of the main beam foam are respectively a C area and a D area, a layer of glue film is wrapped on the main beam foam before paving, the glue films on the upper surface and the lower surface are completely adhered, ironing and compacting are carried out by using an iron, then paving is carried out on the C area and the D area in sequence, the C area is a thickness reduction section of the main beam foam, and the D area is the whole body of the main beam grain foam;
the laying areas of the rear edge foam are respectively an area A and an area B, a layer of adhesive film is wrapped on the rear yard foam before laying, the adhesive film is ironed and compacted by using an iron after being laminated, then the area A and the area B are sequentially laid by using the laminated prepreg, the area A is a thickness reduction section of the rear edge foam, and the area B is the whole body of the rear edge foam;
(6) presetting: placing the front edge foam, the rear edge foam and the main beam foam into a lower die, vacuumizing the lower die, conveying the lower die into an oven for heating, taking out the lower die after heating is finished, closing the oven and a vacuum pump, cutting the vacuum bag, and taking out the spliced preformed body;
(7) lay-up of lower joint area: pre-burying a processed metal piece to a corresponding position of a joint area in a mold, paving a layer of single-sided demolding cloth on the surfaces of joints corresponding to the joint area where an upper mold, a lower mold and an airfoil are located, paving a layer of plain cloth prepreg corresponding to the shape of the joints on the demolding cloth of the lower mold, cutting out at a fold after paving, paving a plurality of layers of prepared small joint prepregs, paving a large joint patch with the same shape as the large joint to fill the step flat, uncovering protective white paper, continuing paving a lower joint patch, and gradually spreading the lower joint patch upwards from large to small to ensure that the metal piece is tightly attached to the prepreg;
(8) paving the skin: taking out the skin which is cut and cloth-combined, confirming an angle, enabling the lower surface of the skin to face upwards, flatly placing the skin on a table top padded with white paper, horizontally placing the preformed body in the skin, enabling the skin to be turned upwards along the front edge of the preformed body to wrap the preformed body, covering the upper surface of the skin with demolding cloth, ironing the upper surface of the skin with an iron until the surface is flat, turning the preformed body by 180 degrees, enabling the other surface of the skin to face upwards, tensioning non-ironed fiber cloth to enable the cloth at the front edge to be tightly attached to the preformed body, ironing the preformed body from the front edge to the rear edge by using the iron, cutting the skin with scissors to be tidy after ironing is finished, and;
(9) laying an upper joint: the minimum upper joint patch is attached to the surface of the skin, the upper joint patches with gradually increasing sizes are sequentially attached, the surface of the skin is smooth after the patches are laid, a plurality of layers of small joint prepreg are laid, finally, a layer of plain cloth prepreg with the same shape as the joint is laid, and a layer of demoulding paper is laid on the surface of the upper joint after the laying is finished;
(10) die assembly: hoisting an upper die by a crane to prepare die assembly, slowly moving the upper die to a position right above a lower die, slowly descending the upper die to a position close to the lower die, inserting a positioning pin, continuously descending the upper die until the upper die and the lower die are combined together, inserting a bolt and a screw after the die assembly is successfully completed, and screwing the bolt and the screw by a wrench;
(11) injecting glue, curing, demoulding and trimming: connecting the mould with a glue injection pipe, heating the mould to 50 ℃, then preserving heat in an oven, starting vacuumizing the mould and resin, injecting epoxy resin glue solution after vacuumizing, controlling the temperature of the oven, curing according to a curing process, cooling to room temperature after curing, opening the mould, taking out the airfoil, and trimming the airfoil to obtain the integrally molded airfoil;
the joint consists of a large joint and a small joint, and the small joint area is the area between the outer edge of the joint and the step.
In order to further enhance the strength of the airfoil, the front edge foam is symmetrically provided with a step in the height direction, a first thickness reduction section is arranged between one end of the front edge foam and the step, in the step (5), the area E corresponds to the first thickness reduction section, 12 groups of prepregs are used for laying the area E, and the laying angles of the prepregs from the first group to the twelfth group (four layers of prepregs in each group) are sequentially as follows: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), (45 °/45 °/0 °/0 °), (45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (-45 °/90 °/0 °/0 °), (90 °/0 °/45 °, (0 °/0 °/45 °), the first group to the sixth group of the prepregs are sequentially paved on the upper surface of the front edge foam, and the seventh group to the twelfth group of the prepregs are sequentially paved on the lower surface of the front edge foam; the paving step of the E area comprises the following steps: sequentially paving the first group to the third group on the upper surface of the front edge foam, and the second step: paving the seventh group to the ninth group on the lower surface of the front edge foam in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
the main beam foam is symmetrically provided with three steps in the height direction, namely a first step, a second step and a third step, a thickness reduction section II is arranged between one end of the upper surface of the main beam foam and the first step, a thickness reduction section III is arranged between the first step and the second step, and a thickness reduction section IV is arranged between the second step and the third step; a thickness reduction section five is arranged between one end of the lower surface of the main beam foam and the step one, a thickness reduction section six is arranged between the step one and the step two, a thickness reduction section seven is arranged between the step two and the step three, the C area is divided into a C1 area, a C2 area, a C3 area, a C4 area, a C5 area and a C6 area, a C1 area corresponds to the thickness reduction section two, a C2 area corresponds to the thickness reduction section three, a C3 area corresponds to the thickness reduction section four, a C4 area corresponds to the thickness reduction section five, a C5 area corresponds to the thickness reduction section six, a C6 area thickness reduction section seven corresponds to the thickness reduction section seven, four layers of prepreg are used for paving the C1 area, and paving angles of the prepregs from a first group to a fourth group (each group of four layers of prepreg) are sequentially: (-45 °/45 °/0 °/90 °), (0 °/45 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °/0 °); two sets of prepregs were used to lay up the C2 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °/0 °), (45 °/0 °/90 °); two sets of prepregs were used to lay up the C3 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °), (90 °/0 °/45 °); four sets of prepregs were used to lay up the C4 area, the lay-up angles for the first to fourth sets of prepregs being in order: (45 °/0 °/90 °), (0 °/45 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °/0 °); two sets of prepregs were used to lay up the C5 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °); two sets of prepregs were used to lay up the C6 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °), (90 °/0 °/45 °); wherein, the thickness reducing section II to the thickness reducing section IV are sequentially paved and pasted;
the trailing edge foam is equipped with a step in the direction of height symmetry, reduces the section eight for thickness between trailing edge foam one end and the step, and the A district reduces the section eight with thickness and corresponds, uses 12 layers of preimpregnation material to spread the A district, and the angle of spreading of first group to twelfth group preimpregnation material is in proper order: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), (45 °/45 °/0 °/0 °), (45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (-45 °/90 °/0 °/0 °), (90 °/0 °/45 °, (0 °/0 °/45 °), the first group of the prepreg to the sixth group of the prepreg are sequentially paved on the upper surface of the rear edge foam, the seventh group of the prepreg to the twelfth group of the prepreg are sequentially paved on the lower surface of the rear edge foam, when paving, the first group of the prepreg is aligned with the thick end of the rear edge foam, and the seventh group of the prepreg is aligned with the thick end of the rear edge foam; the layering step of the area A specifically comprises the following steps: paving the first group to the third group on the upper surface of the rear edge foam in sequence, and the second step: paving the seventh group to the ninth group on the lower surface of the rear edge foam in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
wherein the length direction of the foam is 0 degree.
In order to realize integral layering of all foams, the layering method of the D area specifically comprises the following steps:
the number of layers of the D-area laying layer is n, the number of the corresponding prepreg is D1-Dn when the layers are laid from bottom to top, protective white paper is laid on an operation table board, the edge of D1 is aligned with the edge of main beam foam (the part without the prepreg laid on the protective white paper is placed on the protective white paper), the prepreg is tightly adhered to the protective white paper by ironing with an iron, the prepreg is turned over, a first 90-degree corner is folded, the main beam foam is laid down, the part without the prepreg laid on the table board is hung outside the table board, the corner is ironed and compacted to ensure that the prepreg is completely adhered to the side surface of the main beam foam, the main beam foam is turned over again, the main beam foam is horizontally laid on the table board, the D1 non-laid surface is tensioned, the upper surface of the main beam foam is adhered to the prepreg along the crease, the other side surface is ironed from the crease to the other side surface by the, the steps of pasting D2-Dn are the same as the steps of paving D1, and paving interfaces on each layer are staggered from left to right;
the layering method for zones F and B is the same as for zone D.
As a further improvement of the invention, the number of groups of the D-area laying layers is 6, each group consists of four layers of prepregs, and the laying angles from the first group of prepregs to the sixth group of prepregs are as follows in sequence: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the F area layers is 6, and the layer spreading angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the groups of the B-area laying layers is 6, and the laying angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and successively laying the first set of prepregs to the sixth set of prepregs.
In order to make each layer of prepreg tightly fit, the step (5) further comprises the following vacuumizing step:
(601) first vacuumizing: after the first to third layers of prepreg and the seventh to ninth layers of prepreg in the area A, the first to third groups and the seventh to ninth groups of prepreg in the area E, and the prepreg in the area C1 and the area C4 are laid, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, and the vacuumized vacuum bag is pushed into an oven to be compacted, so that no gap is formed between the prepregs;
(602) and (3) second vacuumizing: after all the prepregs in the area A, the area C and the area E are laid, sequentially putting front edge foams, rear edge foams and main beam foams at the moment from one side of an opening of a vacuum bag at intervals, sealing the opening of the vacuum bag, vacuumizing the vacuum bag, pushing the vacuumized vacuum bag into an oven for compaction, and ensuring that no gap exists among the prepregs;
(603) vacuumizing for the third time: after the first group to the third group of prepreg materials in the area B, the first group to the third group of prepreg materials in the area D and the first group to the third group of prepreg materials in the area F are wrapped, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and no gap is formed between the prepreg materials;
(604) fourth vacuumizing: after all the prepregs in the area B, the area D and the area F are wrapped, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag and are placed at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and therefore no gap exists between the prepregs.
As a further improvement of the present invention, the lower joint patch consists of a lower joint first patch group and a lower joint second patch group, the lower joint first patch group consists of n lower joint first patches Pi, Pi is the ith lower joint first patch, P1 is set to be the largest, the sizes of P1 to Pn are sequentially decreased, Pi is the lower joint first patch cut from one end of P1 along the direction of the other end of P1 by the width of (i-1) × l1 mm, l1 is the first cutting width which is set, P1 to Pn are sequentially paved on the corresponding area of the lower mold, and the other end of P1 is one end with an arc; the second patch group of the lower joint consists of m second patches Sx of the lower joint, the Sx is the xth second patch of the lower joint, the sizes of S1 to Sm are sequentially decreased, the Sx is the first patch of the lower joint which is cut off by (x-1) × l 2mm in width from one end of S1 along the direction of the other end of S1, and l2 is the set cutting width two.
As a further improvement of the present invention, when there are t top tab patches in the step (9), Yu represents the u-th applied top tab patch, Yt is the largest, Yt is the same as P1, Yu is the top tab patch cut from one end of Yt along the direction of the other end of Yt by (t-u) × l 3mm in width, and l3 is the set cut width three.
The invention utilizes the combination of the foam and the prepreg to manufacture the airfoil, and the preparation cost is low; the prepared airfoil has low quality; through the arrangement of the spreading angle of each layer of prepreg, the strength of the airfoil is improved, the bending resistance is good, and the method can be applied to the work of preparing the missile wing of an airplane.
Drawings
FIG. 1 is a perspective view of the leading edge foam, the main beam foam and the trailing edge foam of the present invention after they are brought together.
FIG. 2 is a perspective view of an airfoil made in accordance with the present invention.
Fig. 3 is a schematic structural diagram of a large joint patch of the present invention.
Fig. 4 is a schematic structural view of a first patch P1 of the lower joint of the present invention.
Fig. 5 is a schematic structural view of a second patch S1 of the lower joint of the present invention.
FIG. 6 is a sectioned diagrammatic view of an airfoil according to the invention.
Wherein, 1 step four, 2 rear edge foams, 3 steps one, 4 steps two, 5 main beam foams, 6 front edge foams, 7 steps five, 8 steps three, 9 small joints and 10 large joints.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
A method of making an airfoil comprising the steps of,
(1) preparation of a mold: cleaning residues in the inner cavity of the mold, wiping the inner cavity of the mold by using clean cloth tape soaked acetone after the residues are cleaned, cleaning residues affecting products, wiping the inner cavity of the mold by using the clean cloth tape soaked release agent after the residues are dried, wiping the release agent again after the release agent is dried, repeating the step of wiping the release agent for 5-8 times, and covering the mold with a preservative film for later use;
(2) fabric cutting: cutting the carbon fiber cloth into enough material for the product and reserving spare material according to the shape, quantity and angle requirements of the process file by using a cloth cutting machine, shaping the cut cloth by using a shaping agent after the cutting is finished, numbering by using a marking pen after the shaping, and placing the cloth in a specified area in sequence;
(3) cloth combination: sequentially closing two adjacent layers of cloth, ironing each combined layer by using an electric iron, continuously numbering, and putting the combined layers in sequence;
(4) preparation of the foam: processing front edge foam 6, main beam foam 5 and rear edge foam 2 according to design requirements, cutting the foam appearance by an art designer knife, and polishing by abrasive paper after cutting to ensure that the foam meets the design requirements;
(5) layering in a partitioning manner: paving the front edge foam 6, specifically, paving layers of the front edge foam 6 respectively to form an E area and an F area, wrapping a layer of glue film on the main beam foam 5 before paving, finishing the gluing of the glue films on the upper surface and the lower surface, and then paving layers of the E area and the F area in sequence, wherein the E area is a thickness reduction section of the front edge foam 6, and the F area is the whole body of the front edge foam 6;
the paving areas of the girder foam 5 are respectively a C area and a D area, a layer of glue film is wrapped on the girder foam 5 before paving, the glue films on the upper surface and the lower surface are completely adhered, ironing and compacting are carried out by using an iron, then paving is carried out on the C area and the D area in sequence, the C area is a section with reduced thickness of the girder foam 5, and the D area is the whole body of the girder grain foam;
the laying areas of the rear edge foam 2 are an area A and an area B respectively, a layer of adhesive film is wrapped on the rear yard foam before laying, the adhesive film is ironed and compacted by using an iron after being laminated, then the area A and the area B are laid in sequence by using the laminated prepreg, the area A is a thickness reduction section of the rear edge foam 2, and the area B is the whole body of the rear edge foam 2;
(6) presetting: placing the front edge foam 6, the rear edge foam 2 and the main beam foam 5 into a lower die, vacuumizing the lower die, conveying the lower die into an oven for heating, taking out the lower die after heating is finished, closing the oven and a vacuum pump, cutting the vacuum bag, and taking out the spliced preformed body;
(7) lay-up of lower joint area: pre-burying a processed metal piece to a corresponding position of a joint area in a mold, paving a layer of single-sided demolding cloth on the surfaces of joints corresponding to the joint area where an upper mold, a lower mold and an airfoil are located, paving a layer of plain cloth prepreg corresponding to the shape of the joints on the demolding cloth of the lower mold, cutting out at a fold after paving, paving a plurality of layers of prepared small joint prepregs, paving a large joint patch with the same shape as that of a large joint 10 to fill up a step, uncovering protective white paper, continuing paving a lower joint patch, and gradually increasing the size of the lower joint patch from large to small to upwards paving, so that the metal piece is tightly attached to the prepreg;
(8) paving the skin: taking out the skin which is cut and cloth-combined, confirming an angle, enabling the lower surface of the skin to face upwards, flatly placing the skin on a table top padded with white paper, horizontally placing the preformed body in the skin, enabling the skin to be turned upwards along the front edge of the preformed body to wrap the preformed body, covering the upper surface of the skin with demolding cloth, ironing the upper surface of the skin with an iron until the surface is flat, turning the preformed body by 180 degrees, enabling the other surface of the skin to face upwards, tensioning non-ironed fiber cloth to enable the cloth at the front edge to be tightly attached to the preformed body, ironing the preformed body from the front edge to the rear edge by using the iron, cutting the skin with scissors to be tidy after ironing is finished, and;
(9) laying an upper joint: the minimum upper joint patch is attached to the surface of the skin, the upper joint patches with gradually increasing sizes are sequentially attached, the surface of the skin is smooth after the patches are laid, a plurality of layers of small joint prepreg are laid, finally, a layer of plain cloth prepreg with the same shape as the joint is laid, and a layer of demoulding paper is laid on the surface of the upper joint after the laying is finished;
(10) die assembly: hoisting an upper die by a crane to prepare die assembly, slowly moving the upper die to a position right above a lower die, slowly descending the upper die to a position close to the lower die, inserting a positioning pin, continuously descending the upper die until the upper die and the lower die are combined together, inserting a bolt and a screw after the die assembly is successfully completed, and screwing the bolt and the screw by a wrench;
(11) injecting glue, curing, demoulding and trimming: connecting the mould with a glue injection pipe, heating the mould to 50 ℃, then preserving heat in an oven, starting vacuumizing the mould and resin, injecting epoxy resin glue solution after vacuumizing, controlling the temperature of the oven, curing according to a curing process, cooling to room temperature after curing, opening the mould, taking out the airfoil, and trimming the airfoil to obtain the integrally molded airfoil;
wherein, the joint is composed of a large joint 10 and a small joint 9, and the area of the small joint 9 is the area between the outer edge of the joint and the step.
In this embodiment, the specific steps of glue injection are as follows: the mould is firstly erected and put into an oven (the glue injection opening is downward), and all the pipes and valves to be used are connected; turning off a power supply of the oven, putting the glue into the oven, vacuumizing and heating at the same time, and vacuumizing for 30 minutes; after the vacuumizing is finished, the valve is closed, and a vacuumizing pipe is connected to the mold for vacuumizing; opening the glue injection valve after 30 minutes, and simultaneously opening a standby valve of a glue injection tank to start glue injection; after 3-5 minutes, the flowing glue has no bubbles, an air compressor is started, the power supply of the air compressor is turned off when the pressure reaches 0.4-0.6 MPa, and the pressure starts to be pressed; closing the valves when the glue is discharged from the glue outlet hole, closing all the valves (6), then closing the vacuum pump, and starting to hold the glue; the observation is started 1 time every 15 minutes, the observation is 3-4 times, and the observation is followed 2-3 times every 30 minutes and 1 time. And (5) building glue until the glue outlet valve has no bubble, the glue does not flow in the pipe, all the pipes are removed, and the glue injection is finished.
The front edge foam 6 is symmetrically provided with a step in the height direction, for convenience of distinguishing, the step is called as step five 7, a first thickness reduction section is arranged between one end of the front edge foam 6 and the step, in the step (5), the area E corresponds to the first thickness reduction section, 12 groups of prepregs are used for laying the area E, and the laying angles of the prepregs from the first group to the twelfth group (each group of four layers of prepregs) are sequentially as follows: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), (45 °/45 °/0 °/0 °), (45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (-45 °/90 °/0 °/0 °), (90 °/0 °/45 °, (0 °/0 °/45 °), the first group to the sixth group of the prepregs are sequentially paved on the upper surface of the front edge foam 6, and the seventh group to the twelfth group of the prepregs are sequentially paved on the lower surface of the front edge foam 6; the paving step of the E area comprises the following steps: paving the first group to the third group on the upper surface of the front edge foam 6 in sequence, and the second step: paving the seventh group to the ninth group on the lower surface of the front edge foam 6 in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
the main beam foam 5 is symmetrically provided with three steps in the height direction, namely a step I3, a step II 4 and a step III 8, a thickness reduction section II is arranged between one end of the upper surface of the main beam foam 5 and the step I3, a thickness reduction section III is arranged between the step I3 and the step II 4, and a thickness reduction section IV is arranged between the step II 4 and the step III 8; a thickness reduction section five is arranged between one end of the lower surface of the main beam foam 5 and the step one 3, a thickness reduction section six is arranged between the step one 3 and the step two 4, a thickness reduction section seven is arranged between the step two 4 and the step three 8, the C region is divided into a C1 region, a C2 region, a C3 region, a C4 region, a C5 region and a C6 region, the C1 region corresponds to the thickness reduction section two, the C2 region corresponds to the thickness reduction section three, the C3 region corresponds to the thickness reduction section four, the C4 region corresponds to the thickness reduction section five, the C5 region corresponds to the thickness reduction section six, the thickness reduction section seven of the C6 region corresponds to the thickness reduction section seven, four layers are used for paving the C1 region, and the paving angles from the first group of prepreg to the fourth group of prepreg (each group of four layers of prepreg): (-45 °/45 °/0 °/90 °), (0 °/45 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °/0 °); two sets of prepregs were used to lay up the C2 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °/0 °), (45 °/0 °/90 °); two sets of prepregs were used to lay up the C3 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °), (90 °/0 °/45 °); four sets of prepregs were used to lay up the C4 area, the lay-up angles for the first to fourth sets of prepregs being in order: (45 °/0 °/90 °), (0 °/45 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °/0 °); two sets of prepregs were used to lay up the C5 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °); two sets of prepregs were used to lay up the C6 area, the lay-up angles for the first and second sets of prepregs being: (0 °/45 °/0 °), (90 °/0 °/45 °); wherein, the thickness reducing section II to the thickness reducing section IV are sequentially paved and pasted;
trailing edge foam 2 is equipped with a step in the direction of height symmetry, is called step four 1 below, reduces the section eight for thickness between 2 one end of trailing edge foam and the step four 1, and the A district reduces the section eight with thickness and corresponds, uses 12 layers of preimpregnation material to spread the layer in the A district, and the angle of spreading of first group to twelfth group preimpregnation material is in proper order: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), (45 °/45 °/0 °/0 °), (45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (-45 °/90 °/0 °/0 °), (90 °/0 °/45 °, (0 °/0 °/45 °), the first group to the sixth group of the prepreg are sequentially paved on the upper surface of the rear edge foam 2, the seventh group to the twelfth group of the prepreg are sequentially paved on the lower surface of the rear edge foam 2, when paving, the first group of the prepreg is aligned with the thick end of the rear edge foam 2, and the seventh group of the prepreg is aligned with the thick end of the rear edge foam 2; the layering step of the area A specifically comprises the following steps: the first group to the third group are sequentially paved on the upper surface of the rear edge foam 2, and the second step is as follows: paving the seventh group to the ninth group on the lower surface of the rear edge foam 2 in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
wherein, the length direction (the joint area points to the other side of the foam) of the foam is 0 degree, the anticlockwise rotation of 45 degrees is a layer spreading angle of 45 degrees, the clockwise rotation of 45 degrees is a layer spreading angle of-45 degrees, and the anticlockwise rotation of 90 degrees is a layer spreading angle of 90 degrees.
In order to realize integral layering of all foams, the layering method of the D area specifically comprises the following steps:
the number of layers of the D-area laying layer is n, the number of the corresponding prepreg is D1-Dn when the layers are laid from bottom to top, protective white paper is laid on an operation table board, the edge of D1 is aligned with the edge of the main beam foam 5 (the part without the prepreg is laid on the protective white paper), the prepreg is tightly adhered to the protective white paper by ironing with an iron, the prepreg is turned over and folded to form a first 90-degree corner, the main beam foam 5 is laid down, the part without the prepreg laying layer is perpendicular to the outside of the table board, the corner is ironed and compacted, the prepreg is completely adhered to the side surface of the main beam foam 5, the main beam foam 5 is turned over again, the main beam foam 5 is horizontally laid on the table board, the D1 surface is tensioned, the upper surface of the main beam foam 5 is adhered to the prepreg along the crease, the iron is used for ironing from the crease to the other side surface, the other side surface is adhered and compacted after the lower, the steps of pasting D2-Dn are the same as the steps of paving D1, and paving interfaces on each layer are staggered from left to right;
the layering method for zones F and B is the same as for zone D.
Wherein, the group number that D district laid the layer is 6, and every group comprises four layers of preimpregnation materials, and the layer angle of laying of first group preimpregnation material to sixth group preimpregnation material is in proper order: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the F area layers is 6, and the layer spreading angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the groups of the B-area laying layers is 6, and the laying angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and successively laying the first set of prepregs to the sixth set of prepregs.
In order to make each layer of prepreg tightly fit, the step (5) further comprises the following vacuumizing step:
(601) first vacuumizing: after the first to third layers of prepreg and the seventh to ninth layers of prepreg in the area A, the first to third groups and the seventh to ninth groups of prepreg in the area E, and the prepreg in the area C1 and the area C4 are laid, the front edge foam 6, the rear edge foam 2 and the main beam foam 5 are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, and the vacuumized vacuum bag is pushed into an oven to be compacted, so that no gap is formed between the prepregs;
(602) and (3) second vacuumizing: after all the prepregs in the area A, the area C and the area E are laid, the front edge foam 6, the rear edge foam 2 and the main beam foam 5 are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and therefore no gap is formed among the prepregs;
(603) vacuumizing for the third time: after the first group to the third group of prepreg materials in the area B, the first group to the third group of prepreg materials in the area D and the first group to the third group of prepreg materials in the area F are wrapped, the front edge foam 6, the rear edge foam 2 and the main beam foam 5 are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and no gap is formed between the prepreg materials;
(604) fourth vacuumizing: after all the prepreg in the areas B, D and F is packaged, the front edge foam 6, the rear edge foam 2 and the main beam foam 5 are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and no gap is formed among the prepreg.
The lower joint patch consists of a first lower joint patch group and a second lower joint patch group, wherein the first lower joint patch group consists of n first lower joint patch Pi, the Pi is the ith first lower joint patch, P1 is set to be the largest, the sizes of P1 to Pn are sequentially decreased progressively, the Pi is the first lower joint patch obtained by cutting (i-1) × l1 mm in width from one end of P1 along the direction of the other end of P1 (the direction indicated by an arrow shown in FIG. 4), l1 is the set first cutting width, P1 to Pn are sequentially paved on the corresponding area of a lower die, and the other end of P1 is one end with an arc; the second patch group of the lower joint consists of m second patches Sx of the lower joint, the Sx is the xth second patch of the lower joint, the sizes of S1 to Sm are sequentially reduced, the Sx is the first patch of the lower joint which is cut off by (x-1) × 2mm in width from one end of S1 along the direction of the other end of S1 (the direction indicated by an arrow shown in figure 5), l2 is the set cutting width two, the first patch of the lower joint is larger than the second patch of the lower joint, l1 is preferably 3mm, and n is preferably 28; l2 is preferably 2mm, m is preferably 5.
The number of top tab patches in step (9) is t, Yu represents the u-th paved top tab patch, Yt is the largest, Yt is the same as P1, Yu is the top tab patch cut from one end of Yt along the direction of the other end of Yt (the direction indicated by the arrow shown in fig. 4) by (t-u) | 3mm in width, l3 is the set cut width of three, Yt is the same as P1 in shape, the other end of Yt is the end with a circular arc, l3 is preferably 4mm, and t is preferably 20.
The invention utilizes the combination of the foam and the prepreg to manufacture the airfoil, and the preparation cost is low; the prepared airfoil has low quality; through the arrangement of the spreading angle of each layer of prepreg, the strength of the airfoil is improved, the bending resistance is good, and the method can be applied to the work of preparing the missile wing of an airplane.
The present invention is not limited to the above embodiments, and based on the technical solutions disclosed in the present invention, those skilled in the art can make some substitutions and modifications to some technical features without creative efforts based on the disclosed technical solutions, and these substitutions and modifications are all within the protection scope of the present invention.
Claims (7)
1. A method of making an airfoil comprising the steps of,
(1) preparation of a mold: cleaning residues in the inner cavity of the mold, wiping the inner cavity of the mold by using clean cloth tape soaked acetone after the residues are cleaned, cleaning residues affecting products, wiping the inner cavity of the mold by using the clean cloth tape soaked release agent after the residues are dried, wiping the release agent again after the release agent is dried, repeating the step of wiping the release agent for 5-8 times, and covering the mold with a preservative film for later use;
(2) fabric cutting: cutting the carbon fiber cloth into enough material for the product and reserving spare material according to the shape, quantity and angle requirements of the process file by using a cloth cutting machine, shaping the cut cloth by using a shaping agent after the cutting is finished, numbering by using a marking pen after the shaping, and placing the cloth in a specified area in sequence;
(3) cloth combination: sequentially closing two adjacent layers of cloth, ironing each combined layer by using an electric iron, continuously numbering, and putting the combined layers in sequence;
(4) preparation of the foam: processing front edge foam, main beam foam and rear edge foam according to design requirements, cutting the foam appearance by an art designer knife, and polishing by abrasive paper after cutting to ensure that the foam meets the design requirements;
(5) layering in a partitioning manner: paving the front edge foam, wherein paving areas of the front edge foam are an E area and an F area respectively, before paving, a layer of glue film is wrapped on the main beam foam, the glue films on the upper surface and the lower surface are completely adhered, then paving is carried out on the E area and the F area in sequence, the E area is a thickness reduction section of the front edge foam, and the F area is the whole front edge foam;
the paving areas of the main beam foam are respectively a C area and a D area, a layer of glue film is wrapped on the main beam foam before paving, the glue films on the upper surface and the lower surface are completely adhered, ironing and compacting are carried out by using an iron, then paving is carried out on the C area and the D area in sequence, the C area is a thickness reduction section of the main beam foam, and the D area is the whole body of the main beam grain foam;
the laying areas of the rear edge foam are respectively an area A and an area B, a layer of adhesive film is wrapped on the rear yard foam before laying, the adhesive film is ironed and compacted by using an iron after being laminated, then the area A and the area B are sequentially laid by using the laminated prepreg, the area A is a thickness reduction section of the rear edge foam, and the area B is the whole body of the rear edge foam;
(6) presetting: placing the front edge foam, the rear edge foam and the main beam foam into a lower die, vacuumizing the lower die, conveying the lower die into an oven for heating, taking out the lower die after heating is finished, closing the oven and a vacuum pump, cutting the vacuum bag, and taking out the spliced preformed body;
(7) lay-up of lower joint area: pre-burying a processed metal piece to a corresponding position of a joint area in a mold, paving a layer of single-sided demolding cloth on the surfaces of joints corresponding to the joint area where an upper mold, a lower mold and an airfoil are located, paving a layer of plain cloth prepreg corresponding to the shape of the joints on the demolding cloth of the lower mold, cutting out at a fold after paving, paving a plurality of layers of prepared small joint prepregs, paving a large joint patch with the same shape as the large joint to fill the step flat, uncovering protective white paper, continuing paving a lower joint patch, and gradually spreading the lower joint patch upwards from large to small to ensure that the metal piece is tightly attached to the prepreg;
(8) paving the skin: taking out the skin which is cut and cloth-combined, confirming an angle, enabling the lower surface of the skin to face upwards, flatly placing the skin on a table top padded with white paper, horizontally placing the preformed body in the skin, enabling the skin to be turned upwards along the front edge of the preformed body to wrap the preformed body, covering the upper surface of the skin with demolding cloth, ironing the upper surface of the skin with an iron until the surface is flat, turning the preformed body by 180 degrees, enabling the other surface of the skin to face upwards, tensioning non-ironed fiber cloth to enable the cloth at the front edge to be tightly attached to the preformed body, ironing the preformed body from the front edge to the rear edge by using the iron, cutting the skin with scissors to be tidy after ironing is finished, and;
(9) laying an upper joint: the minimum upper joint patch is attached to the surface of the skin, the upper joint patches with gradually increasing sizes are sequentially attached, the surface of the skin is smooth after the patches are laid, a plurality of layers of small joint prepreg are laid, finally, a layer of plain cloth prepreg with the same shape as the joint is laid, and a layer of demoulding paper is laid on the surface of the upper joint after the laying is finished;
(10) die assembly: hoisting an upper die by a crane to prepare die assembly, slowly moving the upper die to a position right above a lower die, slowly descending the upper die to a position close to the lower die, inserting a positioning pin, continuously descending the upper die until the upper die and the lower die are combined together, inserting a bolt and a screw after the die assembly is successfully completed, and screwing the bolt and the screw by a wrench;
(11) injecting glue, curing, demoulding and trimming: connecting the mould with a glue injection pipe, heating the mould to 50 ℃, then preserving heat in an oven, starting vacuumizing the mould and resin, injecting epoxy resin glue solution after vacuumizing, controlling the temperature of the oven, curing according to a curing process, cooling to room temperature after curing, opening the mould, taking out the airfoil, and trimming the airfoil to obtain the integrally molded airfoil;
the joint consists of a large joint and a small joint, and the small joint area is the area between the outer edge of the joint and the step.
2. The method for manufacturing an airfoil according to claim 1, wherein the leading edge foam is symmetrically provided with a step in the height direction, a first thickness reduction section is arranged between one end of the leading edge foam and the step, in the step (5), the area E corresponds to the first thickness reduction section, 12 groups of prepregs are used for laying the area E, and the laying angles of the prepregs from the first group to the twelfth group are as follows: -45 °/45 °/0 °/0 °, -45 °/0 °/90 °, 0 °/0 °/90 °/45 °, 45 °/90 °/0 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °, 45 °/45 °/0 °/0 °, 45 °/45 °/0 °/90 °, 0 °/0 °/90 °/45 °, -45 °/90 °/0 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °, first to sixth groups of prepregs are sequentially laid on the upper surface of the leading edge foam, the seventh group to the twelfth group are sequentially paved on the lower surface of the front edge foam; the paving step of the E area comprises the following steps: sequentially paving the first group to the third group on the upper surface of the front edge foam, and the second step: paving the seventh group to the ninth group on the lower surface of the front edge foam in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
the main beam foam is symmetrically provided with three steps in the height direction, namely a first step, a second step and a third step, a thickness reduction section II is arranged between one end of the upper surface of the main beam foam and the first step, a thickness reduction section III is arranged between the first step and the second step, and a thickness reduction section IV is arranged between the second step and the third step; the thickness reduction section five is arranged between one end of the lower surface of the main beam foam and the step one, the thickness reduction section six is arranged between the step one and the step two, the thickness reduction section seven is arranged between the step two and the step three, the C area is divided into a C1 area, a C2 area, a C3 area, a C4 area, a C5 area and a C6 area, a C1 area corresponds to the thickness reduction section two, a C2 area corresponds to the thickness reduction section three, a C3 area corresponds to the thickness reduction section four, a C4 area corresponds to the thickness reduction section five, a C5 area corresponds to the thickness reduction section six, the thickness reduction section seven corresponds to the C6 area, four layers of prepreg are used for paving the C1 area, and paving angles from the first group of prepreg to the fourth group of prepreg are sequentially: -45 °/45 °/0 °/90 °, 0 °/45 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °/0 °; two sets of prepregs were used to lay up the C2 area, the lay-up angles for the first and second sets of prepregs being: 0 °/45 °/0 °/0 °, 45 °/0 °/90 °; two sets of prepregs were used to lay up the C3 area, the lay-up angles for the first and second sets of prepregs being: 0 °/45 °/0 °, 90 °/0 °/45 °; four sets of prepregs were used to lay up the C4 area, the lay-up angles for the first to fourth sets of prepregs being in order: 45 °/0 °/90 °, 0 °/45 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °/0 °; two sets of prepregs were used to lay up the C5 area, the lay-up angles for the first and second sets of prepregs being: 0 °/45 °/0 °/0 °, -45 °/45 °/0 °/90 °; two sets of prepregs were used to lay up the C6 area, the lay-up angles for the first and second sets of prepregs being: 0 °/45 °/0 °, 90 °/0 °/45 °; wherein, the thickness reducing section II to the thickness reducing section IV are sequentially paved and pasted;
the trailing edge foam is equipped with a step in the direction of height symmetry, reduces the section eight for thickness between trailing edge foam one end and the step, and the A district reduces the section eight with thickness and corresponds, uses 12 layers of preimpregnation material to spread the A district, and the angle of spreading of first group to twelfth group preimpregnation material is in proper order: -45 °/45 °/0 °/0 °, -45 °/0 °/90 °, 0 °/0 °/90 °/45 °, 45 °/90 °/0 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °, 45 °/45 °/0 °/0 °, 45 °/45 °/0 °/90 °, 0 °/0 °/90 °/45 °, -45 °/90 °/0 °/0 °, 90 °/0 °/45 °, 0 °/0 °/45 °, first to sixth sets of prepregs are sequentially laid on the upper surface of the trailing edge foam, the seventh group to the twelfth group of the prepreg are sequentially paved on the lower surface of the rear edge foam, when the prepreg is paved, the first group of the prepreg is aligned with the thick end of the rear edge foam, and the seventh group of the prepreg is aligned with the thick end of the rear edge foam; the layering step of the area A specifically comprises the following steps: paving the first group to the third group on the upper surface of the rear edge foam in sequence, and the second step: paving the seventh group to the ninth group on the lower surface of the rear edge foam in sequence, and the third step: continuously paving the fourth group to the sixth group on the upper surface in sequence; the fourth step: continuously and sequentially paving the tenth to twelfth groups of prepreg on the lower surface;
wherein the length direction of the foam is 0 degree.
3. The method for preparing an airfoil according to claim 2, wherein the D-region layering method is specifically as follows:
the number of layers of the D area laying layer is n, the number of the corresponding prepreg is D1-Dn when the layers are laid from bottom to top, protective white paper is laid on an operation table board, the edge of D1 is aligned with the edge of main beam foam, the prepreg is firmly adhered to the protective white paper by ironing with an iron, the prepreg is turned over and folded to form a first 90-degree corner, the main beam foam is laid down, the part where the prepreg is not laid is hung outside the table board, the corner is ironed and compacted to ensure that the prepreg is completely adhered to the side surface of the main beam foam, the main beam foam is turned over again, the main beam foam is flatly laid on the table board, the D1 non-laid surface is tensioned, the upper surface of the main beam foam is adhered to the prepreg along the crease, the iron is used for ironing from the crease to the other side surface, the other side surface is adhered and compacted after the ironing is well, the other side surface is adhered and compacted by an art designer, and, the paving interfaces of each layer are staggered left and right;
the layering method for zones F and B is the same as for zone D.
4. The method for manufacturing the airfoil according to claim 3, wherein the number of groups of D-zone layups is 6, each group is composed of four layers of prepregs, and the layup angles of the first group of prepregs to the sixth group of prepregs are as follows: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the F area layers is 6, and the layer spreading angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (ii) (45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and sequentially laying the first set of prepregs to the sixth set of prepregs;
the number of the groups of the B-area laying layers is 6, and the laying angles from the first group of prepreg to the sixth group of prepreg are as follows in sequence: (-45 °/45 °/0 °/0 °), (-45 °/45 °/0 °/90 °), (0 °/0 °/90 °/45 °), (45 °/90 °/0 °/0 °), (90 °/0 °/45 °), (0 °/0 °/45 °), and successively laying the first set of prepregs to the sixth set of prepregs.
5. The method for manufacturing an airfoil according to claim 4, wherein said step (5) further comprises the following step of evacuating:
(601) first vacuumizing: after the first to third layers of prepreg and the seventh to ninth layers of prepreg in the area A, the first to third groups and the seventh to ninth groups of prepreg in the area E, and the prepreg in the area C1 and the area C4 are laid, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, and the vacuumized vacuum bag is pushed into an oven to be compacted, so that no gap is formed between the prepregs;
(602) and (3) second vacuumizing: after all the prepregs in the area A, the area C and the area E are laid, sequentially putting front edge foams, rear edge foams and main beam foams at the moment from one side of an opening of a vacuum bag at intervals, sealing the opening of the vacuum bag, vacuumizing the vacuum bag, pushing the vacuumized vacuum bag into an oven for compaction, and ensuring that no gap exists among the prepregs;
(603) vacuumizing for the third time: after the first group to the third group of prepreg materials in the area B, the first group to the third group of prepreg materials in the area D and the first group to the third group of prepreg materials in the area F are wrapped, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and no gap is formed between the prepreg materials;
(604) fourth vacuumizing: after all the prepregs in the area B, the area D and the area F are wrapped, the front edge foam, the rear edge foam and the main beam foam are sequentially placed from one side of an opening of a vacuum bag and are placed at intervals, the opening of the vacuum bag is sealed, the vacuum bag is vacuumized, the vacuumized vacuum bag is pushed into an oven to be compacted, and therefore no gap exists between the prepregs.
6. The method for manufacturing an airfoil according to any one of claims 1 to 5, wherein the lower joint patch consists of a first lower joint patch group and a second lower joint patch group, the first lower joint patch group consists of n first lower joint patches Pi, Pi is the ith first lower joint patch, P1 is set to be the largest, the sizes of P1 to Pn are sequentially decreased, Pi is the first lower joint patch which is cut off by (i-1) × l1 mm in width along the direction of the other end of P1 from one end of P1, l1 is the set cutting width one, P1 to Pn are sequentially paved on the corresponding area of the lower die, and the other end of P1 is one end with a circular arc; the second patch group of the lower joint consists of m second patches Sx of the lower joint, the Sx is the xth second patch of the lower joint, the sizes of S1 to Sm are sequentially decreased, the Sx is the first patch of the lower joint which is cut off by (x-1) × l 2mm in width from one end of S1 along the direction of the other end of S1, and l2 is the set cutting width two.
7. The method of claim 6, wherein the number of the top tab patches in the step (9) is t, and Yu represents the u-th applied top tab patch, so that Yt is the maximum, Yt is the same as P1, Yu is the top tab patch cut from one end of Yt along the direction of the other end of Yt by a width of (t-u) × l 3mm, and l3 is the set cut width of three.
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