CN114311750B - Method for producing blade preform, molding die, and method for producing rotor - Google Patents
Method for producing blade preform, molding die, and method for producing rotor Download PDFInfo
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- CN114311750B CN114311750B CN202111674488.2A CN202111674488A CN114311750B CN 114311750 B CN114311750 B CN 114311750B CN 202111674488 A CN202111674488 A CN 202111674488A CN 114311750 B CN114311750 B CN 114311750B
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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Abstract
The invention discloses a preparation method of a blade preformed body, a forming die and a method for preparing a rotor, and an upstream surface preformed body and a downstream surface preformed body are obtained; the blade root of the upstream surface preformed body is provided with a first flanging far away from the central surface of the blade, and the blade root of the downstream surface preformed body is provided with a second flanging far away from the central surface of the blade; closing the die of the upstream surface preformed body and the downstream surface preformed body, and performing pre-curing to obtain a blade preformed body with a first flanging and a second flanging; the plurality of blade preformed bodies are used for being connected with the periphery of a hub of the rotor, the plurality of blade preformed bodies are radially arranged with the central shaft of the hub as the center, the first flanging of each blade preformed body is used for being connected with the periphery of the hub preformed body, and the second flanging of each blade preformed body is used for being connected with the first flanging of the adjacent blade preformed body. The invention reduces the debonding risk of the blade and the hub, improves the service life and increases the limit revolution; and simultaneously, the connection strength of the blade and the hub is also provided.
Description
Technical Field
The invention belongs to the technical field of composite material blade forming, and particularly relates to a preparation method of a blade preform, a forming die and a method for preparing a rotor.
Background
The propeller is an important structure of a nuclear submarine or torpedo, and the propeller plays a role by driving the rotation of the blades by the rotor, most of the rotor blades are made of metal materials at present, the weight of the product is heavy, the fatigue performance and the corrosion resistance are poor, and the limit rotation speed of the blades is influenced. The rotor blade made of the composite material has the characteristics of light weight and high rigidity, has excellent fatigue performance and corrosion resistance, and can obviously improve the safety and the service life of the propeller.
At present, the preparation process of the rotor of the propeller comprises the following steps: a preform of the blade and the hub is obtained first, wherein the outer circumference of the rotor preform has grooves for connection with the blade, but this connection leads to a low connection strength of the blade and the hub, which is easily debonded.
Disclosure of Invention
In order to solve the technical problems, the invention provides a preparation method of a blade preform, a forming die and a method for preparing a rotor, which improve the connection strength of a blade and a hub, reduce the debonding risk of the blade and the hub, improve the service life and improve the limit revolution.
The technical scheme of the invention is as follows:
in a first aspect, the present invention provides a method of preparing a blade preform, the method comprising:
obtaining an upstream surface preform and a downstream surface preform; the blade root of the upstream surface preformed body is provided with a first flanging far away from the central surface of the blade, and the blade root of the downstream surface preformed body is provided with a second flanging far away from the central surface of the blade;
closing the upstream surface preformed body and the downstream surface preformed body, and performing pre-curing to obtain a blade preformed body with a first flanging and a second flanging;
the blade preforms are connected with the periphery of a hub of the rotor, the blade preforms are radially arranged with the central axis of the hub as the center, the first flanges of the blade preforms are connected with the periphery of the hub preform, and the second flanges of the blade preforms are connected with one side, away from the central axis of the hub, of the adjacent first flanges of the blade preforms.
Further, the thickness of the first flange is smaller than the thickness of the second flange, and the second flange of each blade preform is used for contacting with the blade root of an adjacent blade preform.
Further, the thickness of the first flanging is 1-2mm, and the thickness of the second flanging is 1.2-3mm.
Further, the length of the first turn along the circumferential direction of the hub does not exceed the length of the second turn along the circumferential direction of the hub.
Further, the obtaining the upstream-side preform and the downstream-side preform includes:
obtaining a plurality of upstream surface templates and a plurality of downstream surface templates, wherein the upstream surface templates are matched with the sizes of the to-be-paved layers of a plurality of upstream surfaces of a downstream surface forming die one by one; the back surface templates are matched with the sizes of the to-be-paved layers of the back surface surfaces of the back surface forming die one by one;
the prepreg cloth which is matched with the following edges, the guide edges and the blade tip sizes of the upstream surface templates one by one is paved on the surface of the upstream surface forming die in sequence from the bottom layer to the upper layer, and in each layer of paving, one side of the prepreg cloth, which is close to the blade root, is turned over in the direction away from the central surface of the blade so as to form a upstream surface preformed body with a first flanging;
and (3) laying prepreg cloth matched with the following edges, the guide edges and the blade tip sizes of the plurality of back surface templates one by one on the surface of the back surface forming die in sequence from the bottom layer to the upper layer, wherein in each layer of laying, one side of the prepreg cloth, which is close to the blade root, is turned over in a direction away from the central surface of the blade so as to form a back surface preformed body with a second flanging.
Further, the thickness of the template is 0.3-0.5mm.
Further, the prepreg cloth comprises plain cloth and unidirectional cloth, and the layers formed by the plain cloth and the layers formed by the unidirectional cloth are alternately arranged.
Further, the thickness of each of the plies is 0.23-0.26mm; the distance between the edges of two adjacent layers is less than or equal to 5mm.
In a second aspect, the present invention provides a forming die for preparing the above-mentioned blade preform, where the forming die includes an upstream surface forming die and a downstream surface forming die, the upstream surface forming die has a profile matching the above-mentioned upstream surface preform, and the downstream surface forming die has a profile matching the above-mentioned upstream surface preform.
In a third aspect, the present invention also provides a method for preparing a rotor using the above blade preform, the method comprising:
obtaining a hub preform;
and (3) enabling the first flanging of the plurality of blade preformed bodies to be in contact with the periphery of the hub preformed body, enabling the second flanging of each blade preformed body to be arranged on one side, far away from the central shaft of the hub, of the first flanging of the adjacent blade preformed body, and performing compression curing molding to obtain the rotor.
The beneficial effects of the invention at least comprise:
the preparation method of the blade preformed body provided by the invention comprises the following steps: obtaining an upstream surface preform and a downstream surface preform; the blade root of the upstream surface preformed body is provided with a first flanging far away from the central surface of the blade, and the blade root of the downstream surface preformed body is provided with a second flanging far away from the central surface of the blade; closing the upstream surface preformed body and the downstream surface preformed body, and performing pre-curing to obtain a blade preformed body with a first flanging and a second flanging; the blade preforms are connected with the periphery of a hub of the rotor, the blade preforms are radially arranged with the central axis of the hub as the center, the first flanges of the blade preforms are connected with the periphery of the hub preform, and the second flanges of the blade preforms are connected with one side, away from the central axis of the hub, of the adjacent first flanges of the blade preforms. The first flanging and the second flanging are both arranged far away from the center plane of the blade, so that the first flanging can be in contact with the periphery of the hub preformed body, the second flanging is connected with one side, far away from the center axis, of the adjacent first flanging, after the blade preformed body is in contact with the hub preformed body and is solidified, resin in the preformed body can be melted and interpenetrated between the hub preformed body and the blade preformed body, and a rotor can be formed after pressurization and solidification. The second flanging, the first flanging and the propeller hub are sequentially arranged along the radial direction, the upstream surface of the blade can be subjected to the pressure of water transmission towards the upstream surface in the underwater rotation process of the rotor, so that the first flanging connected with the upstream surface is subjected to the first pressure away from the center shaft of the propeller hub, the downstream surface of the blade can be subjected to the pressure away from the downstream surface, the second flanging connected with the downstream surface is subjected to the second pressure towards the center shaft of the propeller hub, and because the second flanging is arranged on one side of the first flanging away from the center shaft, the second pressure towards the center shaft of the second flanging is opposite to the first pressure of the first flanging away from the center shaft, the second pressure can be partially offset, and the pressure of stripping the blade from the propeller hub is reduced, so that the rotor can stably run; in addition, the connection area of the first flanging and the periphery of the hub is larger than the connection area of the traditional blade root inserted into the groove of the hub, so that the connection strength between the hub and the blade is improved. The invention improves the connection strength of the blade and the hub, reduces the debonding risk of the blade and the hub, prolongs the service life and improves the limit rotating speed.
Drawings
Fig. 1 is a schematic structural view of a rotor.
Fig. 2 is a process step diagram of a method for manufacturing a blade preform according to this embodiment.
FIG. 3 is a cross-sectional view of a blade preform.
Fig. 4 is a schematic view of the structure of the blade preform of fig. 1.
FIG. 5 is a cross-sectional view of the blade preform and pulp hoop preform connection of FIG. 1.
Fig. 6 is a schematic view of the structure of the upstream surface forming die.
Fig. 7 is a schematic view of the structure of the back surface molding die.
Reference numerals illustrate: 1-a blade preform, 11-a first flanging, 12-a second flanging; 2-hub preform; 4-rotor mold; 5-forming die, 51-upstream surface forming die, 511-upstream surface forming die, 512-first forming die, 52-upstream surface forming die, 521-upstream surface forming die and 522-second forming die; 6-blade, 7-pulp hoop.
Detailed Description
In order to make the technical solution more clearly understood by those skilled in the art, the following detailed description is made with reference to the accompanying drawings.
Fig. 1 shows a structure of a rotor, and in combination with fig. 1, the rotor includes a hub 7 and a plurality of blades 6, wherein blade roots of the plurality of blades 6 are connected to an outer periphery of the hub, and the plurality of blades 6 are uniformly distributed radially about a central axis of the hub 7. As can be seen from 1 and fig. 3, the outer diameter of the hub 7 is sequentially reduced along the axial direction, the thickness of the blade 6 of the propeller is uneven, the thickness range is 1-5mm, wherein the thickness of the blade tip of the blade 6 is 0.8-3.5mm, the thickness of the blade root of the blade 6 is 4.5-5.5mm, the center radius of the blade 6 is 500-1000mm, the curvature of the blade is changed, the curvature range of the upstream surface of the blade 6 is-11.50-0.0137, the curvature range of the downstream surface of the blade is-11.66-0.0231, and the thickness and curvature are changed, so that the prepreg is paved on the molded surface of the molding die by adopting variable-dimension variable-curvature pavement, the prepreg is difficult to be directly paved on the molded surface by manpower, the accurate grasping of the paving precision is extremely easy, the profile difference and the weight deviation of the molded blade are extremely easy, great noise is generated when the blade is used for underwater high-speed rotation, and the dynamic balance of rotation is also influenced; in the manufacturing process of the rotor, a blade preform and a hub preform are obtained, wherein the periphery of the rotor preform is provided with a groove for connecting with the blade preform, then the blade root of the blade preform is inserted into the groove of the slurry hoop preform, and then the blade root of the blade preform is pressed and solidified, and the connecting mode leads to low connection strength of the blade and the hub and short service life.
The embodiment of the invention provides a method for preparing a blade preform, fig. 2 is a process step diagram of the method for preparing the blade preform provided in the embodiment, and in combination with fig. 2, the method includes:
s1, obtaining a plurality of upstream surface templates and a plurality of downstream surface templates, wherein the upstream surface templates are matched with the sizes of a plurality of upstream surfaces to be paved of a downstream surface forming die one by one; the back surface templates are matched with the sizes of the to-be-paved layers of the back surface surfaces of the back surface forming die one by one;
because the thickness and the contour degree of the blade are ensured by the step-down ply in the ply laying process, and the ply laying process lacks a ply positioning reference, the upstream surface sample plate and the downstream surface sample plate for the ply laying can be used as ply laying references of the prepreg cloth to determine the cutting size required by each layer of the prepreg cloth, so that the formed blade has small weight deviation and good contour degree. The outline dimensions of the upstream surface template and the back surface template can also be used as the dimension boundary of the layering template by taking steps, lower limits and the like on the die, so as to prepare the layering template.
Further, the thickness of the template is 0.3-0.5mm.
The thickness of the template is matched with the curvature of the blade, if the thickness of the template is too large, the profile is poor, the noise is large when the template rotates at a high speed under water, and the weight deviation of the blade is large, so that the dynamic balance of the rotation of the rotor is influenced.
Further, in the present embodiment, the fibers and resin used for the upstream-face template and the downstream-face template may be any of the following: glass fibers, carbon fibers, basalt fibers, aramid fibers, phenolic resins, epoxy resins, and unsaturated polyester resins; the upstream surface template and the downstream surface template are prepared into skins by adopting the materials, and then cut according to a decreasing layering process to obtain the corresponding layering template.
The dimensions of the upstream and downstream panels may be obtained by drawing a blade of a target size in CAD or three-dimensional software, and calculating the number of layers required for the ply, the amount of decrease between different plies, and the thickness of each ply based on the thickness of the blade.
The template made of the material has certain rigidity and flexibility, so that the skin can be attached to the molded surface to form the curvature matched with the molded surface. When the upstream face template is manufactured, alkali-free glass fiber-barium phenolic prepreg cloth is paved on the molded surface of the upstream face molding die, a skin is cut according to the size of the molded surface, a bottommost upstream face template paving layer is obtained, then a separation film is paved on the bottommost upstream face paving layer, alkali-free glass fiber-barium phenolic prepreg cloth is paved on the separation film, a second alkali-free glass fiber-barium phenolic prepreg cloth is cut according to the calculated reduction amount, a second upstream face template paving layer is formed, the separation film is paved on the second upstream face template paving layer, and the steps are repeated until the uppermost upstream face template paving layer is obtained; after curing, the separation film is removed to obtain a plurality of water facing surface templates. Similarly, a plurality of back surface templates matched with the surface of the back surface forming die can be obtained by adopting the method, and details are not repeated here. Because the template has flexibility and good rigidity, the template can be paved on the molded surface to ensure that the template has curvature matched with the molded surface.
S2, laying prepreg cloth which is matched with the following edges, the guide edges and the blade tip sizes of a plurality of upstream surface templates one by one on the molded surface of the upstream surface molding die in sequence from a bottom layer to an upper layer, and turning over one side of the prepreg cloth, which is close to the blade root, in each layer of laying to a direction away from the central surface of the blade so as to form an upstream surface preformed body with a first flanging;
and (3) laying prepreg cloth matched with the following edges, the guide edges and the blade tip sizes of the plurality of back surface templates one by one on the surface of the back surface forming die in sequence from the bottom layer to the upper layer, wherein in each layer of laying, one side of the prepreg cloth, which is close to the blade root, is turned over in a direction away from the central surface of the blade so as to form a back surface preformed body with a second flanging.
Specifically, laying prepreg cloth on the molded surface of a water-facing surface forming die, cutting the leading edge, the trailing edge and the blade tip of the prepreg cloth in the water-facing surface forming die according to a water-facing surface template corresponding to a water-facing surface to be laid of a first layer, and turning over one side of the prepreg cloth, which is close to a blade root, in a direction away from the central surface of the blade to form the laying of the first layer of water-facing surface layer with a turned edge;
and paving the prepreg on the paved upstream surface paving layer, cutting the leading edge, the trailing edge and the blade tip of the prepreg paved on the upstream surface paving layer according to a downstream surface template corresponding to the downstream surface to be paved, turning over one side of the prepreg close to the blade root part in the direction away from the central surface of the blade and paving the turned over edge on the upper layer to form the paving of the downstream surface paving layer with the turned over edge, and repeating the steps until the paving of the final upstream surface paving layer is completed.
Similarly, the paving of the back surface layer is specifically as follows:
laying prepreg cloth on the molded surface of a back surface molding die, cutting the leading edge, the trailing edge and the blade tip of the prepreg cloth in the back surface molding die according to a back surface template corresponding to the back surface to be laid of the first layer, and turning over one side of the prepreg cloth, which is close to the blade root, in a direction away from the central surface of the blade to form the laying of the first layer of back surface layer with a turned edge;
and paving the prepreg on the paved back surface paving layer, cutting the leading edge, the trailing edge and the blade tip of the prepreg paved on the paved back surface forming die layer according to a back surface template corresponding to the back surface to be paved on the next back surface layer, turning over one side of the prepreg close to the blade root part in the direction away from the central surface of the blade and paving the turned over edge on the last layer to form the paving of the next back surface paving layer with turned edges, and repeating the steps until the paving of the last back surface paving layer is completed.
The thickness between any two layers is the same or similar.
The upstream and downstream templates may be used as fiducials for each ply drop to ensure that the curvature of the resulting blade is consistent with the design dimensions.
Further, in the present embodiment, the prepreg cloth includes plain cloth and unidirectional cloth, and the ply made of the plain cloth is alternately arranged with the ply made of the unidirectional cloth.
The prepreg cloth only adopts plain cloth, the mechanical properties of the plain cloth in all directions are balanced, but the rigidity of the blade manufactured by the plain cloth does not meet the design requirement, and the unidirectional prepreg cloth has high rigidity, so that the rigidity of the blade can be improved by matching the plain cloth with the unidirectional cloth, and other performances are not reduced.
Further, in this embodiment, the unidirectional cloth is laid in a direction from the blade root to the blade tip.
Further, in this embodiment, the thickness of each of the plies is 0.23-0.26mm.
The thickness of each layer is too thick, which is easy to cause poor profile; the thickness of each layer is too thin, delamination easily occurs in the inside of the blade, compaction is not easy, and the rigidity of the blade is reduced.
Further, in this embodiment, the corresponding edge distances of two adjacent plies are less than or equal to 5mm.
The corresponding edge distances of two adjacent layers are determined according to the curvature, and if the edge distances of the two adjacent layers are too large or too small, deviations from the design dimensions of the blade can be generated, so that the problems of weight deviation and profile difference occur.
Further, in this embodiment, the blade root of the upstream-surface preform has a first flange far from the blade center plane, and the blade root of the downstream-surface preform has a second flange far from the blade center plane;
s3, the upstream surface preformed body and the downstream surface preformed body are matched, and are subjected to pre-curing to obtain a blade preformed body 1 with a first flanging 11 and a second flanging 12;
fig. 4 is a schematic structural view of the blade preform of fig. 1, fig. 5 is a sectional view of the connection between the blade preform and the shroud preform of fig. 1, and, in combination with fig. 4 and 5, a plurality of blade preforms 1 are used for connection to the hub periphery of the rotor, a plurality of blade preforms 1 are radially disposed about the center axis of the hub preform 2, a first flange 11 of a blade preform 1 is used for connection to the periphery of the hub preform 2, and a second flange 12 of a blade preform 1 is used for connection to a side of the first flange 11 of an adjacent blade preform 1 away from the center axis of the hub preform 2. In the present invention, the blade center surface means a surface where the upstream surface preform and the downstream surface preform are in contact with each other. The first flange 11 and the second flange 12 are both arranged away from the blade center plane, so that the first flange 11 can be in contact with the outer periphery of the hub preform 2, and the second flange 12 is connected to the side of the adjacent first flange 11 away from the center axis, which contacts and solidifies the blade preform 1 with the hub preform 2, the resin in the preform can melt and interpenetrate between the hub preform 2 and the blade preform 1, and a rotor can be formed after pressurization solidification. The second flange 12, the first flange 11 and the rotor hub are sequentially arranged along the radial direction, in the underwater rotation process of the rotor, the upstream surface of the blade can be subjected to the pressure of water transmission towards the upstream surface, so that the first flange 11 connected with the upstream surface is subjected to the first pressure away from the central axis of the rotor hub preform 2, the downstream surface of the blade can be subjected to the pressure away from the downstream surface, so that the second flange 12 connected with the downstream surface is subjected to the second pressure towards the central axis of the rotor hub, and because the second flange 12 is arranged on one side of the first flange 11 away from the central axis, the second pressure of the second flange 12 towards the central axis is opposite to the first pressure of the first flange 11 away from the central axis, and can be partially offset, and the second pressure is the component of the water pressure received by the downstream surface of the blade in the axial direction of the rotor hub, so that the pressure of stripping the blade from the rotor hub is reduced, and the rotor can stably run; in addition, the connection area between the first flange 11 and the periphery of the hub is larger than that of the conventional hub groove, and therefore the connection strength between the hub 7 and the blade 6 is improved. If the first flange 11 and the second flange 12 are both connected with the periphery of the hub preform 2, the connection area between the hub 7 and the blade 6 can be increased, but in the underwater rotation process of the rotor, the first flange 11 bears the first pressure far away from the central axis of the hub 7, the second flange 12 bears the second pressure towards the central axis of the hub, partial pressure offset cannot occur, and the operation of the second flange 12 pressed on the first flange 11 is not stable.
Further, in the present embodiment, the thickness of the first flange 11 is smaller than the thickness of the second flange 12; and the second flange 12 of each of said blade preforms 1 is intended to be in contact with the blade root of an adjacent blade preform 1.
Specifically, the side of the second flange 12 of each blade preform 1 away from the blade center surface contacts with the blade root on the upstream surface side of the adjacent blade preform 1, so that two adjacent blade preforms 1 can be lapped together, and thus after pressurization and solidification, the side of the second flange 12 close to the pulp hoop can be connected with the first flange 11, and the side of the second flange 12 along the radial direction of the pulp hoop can be connected with the blade root on the upstream surface side of the adjacent blade, so that the connection strength between the adjacent blades can be improved; if there is a gap between the second flange 12 and the blade root of an adjacent blade, the first pressure of the first flange 11 at the gap does not counteract the second pressure of the corresponding second flange 12, which increases the risk of de-binding the blade from the hub. The thickness of the first flanging 11 is larger than that of the second flanging 12, so that the connection area between the second flanging 12 and the blade root of the adjacent blade can be increased, and the connection strength is improved.
Further, in this embodiment, the thickness of the first flange 11 is 0.8-1.2mm, and the thickness of the second flange 12 is 1.2-3mm. The length of the first flange 11 is 20-40mm, and the length of the second flange 12 is 20-40mm.
The lengths of the first and second rims 11 and 12 may be determined according to the number of blades 6 to which the hub 7 is connected, and the lengths of the first and second rims 11 and 12 are shorter when the number of blades 6 is large and the lengths of the first and second rims 11 and 12 are longer when the number of blades 6 is small.
Further, in the present embodiment, the length of the first flange 11 along the circumferential direction of the hub 7 does not exceed the length of the second flange 12 along the circumferential direction of the hub 7.
In a second aspect, an embodiment of the present invention further provides a forming die, for preparing the above-mentioned blade preform 1, fig. 6 is a schematic structural diagram of an upstream surface forming die, fig. 7 is a schematic structural diagram of a downstream surface forming die, and in combination with fig. 6 and fig. 7, the forming die includes an upstream surface forming die 51 and a downstream surface forming die 52, the upstream surface forming die has an upstream surface profile 511 matching the upstream surface preform, and the downstream surface forming die 52 has a downstream surface profile 521 matching the upstream surface preform.
The upstream surface forming die 51 may be provided with a first profile 512 corresponding to the first flange 11, and the downstream surface forming die 52 may be provided with a second profile 522 corresponding to the second flange 12.
In a third aspect, an embodiment of the present invention further provides a method for preparing a rotor using the above-described blade preform, where the method includes:
obtaining a hub preform 2;
the first flanges 11 of the plurality of blade preforms 1 are contacted with the periphery of the hub preform 2, and the second flanges 12 of each blade preform 1 are arranged on one side, away from the central axis of the hub, of the first flanges 11 of the adjacent blade preforms 1, and are subjected to compression curing molding, so that a rotor is obtained.
In the curing molding process, the blade preform 1 and the hub preform 2 are both set in the rotor mold 4, and the resin in the blade preform 1 and the hub preform 2 is melted at high temperature to infiltrate into the blade preform 1 and the hub preform 2 to form a rotor in which the blade 6 and the hub 4 are cured as one body.
The curing and forming are carried out under the vacuum condition, and the curing temperature is less than or equal to 195 ℃.
The blade forming method provided in the present application will be further described with reference to specific examples.
Example 1
Example 1 provides a process for the preparation of the transition to the following steps:
step 1, paving alkali-free glass fiber-barium phenolic aldehyde prepreg cloth with the thickness of 0.4mm on the surface of a water-facing surface forming die, and cutting to obtain a water-facing surface template paving layer of a bottom layer; paving a separation film on the water-facing surface template paving layer of the bottom layer, paving a second alkali-free glass fiber-barium phenolic prepreg cloth on the separation film, performing color cutting according to the designed size and the size reduction of the water-facing surface paving layer of the bottom layer to obtain a second water-facing surface template paving layer, paving the separation film on the second water-facing surface template paving layer, paving a third alkali-free glass fiber-barium phenolic prepreg cloth, and analogizing to obtain 50 water-facing surface template paving layers; after the layering and curing of the 50 layers of water facing surface templates, removing the separation films to obtain 50 water facing surface templates, numbering the water facing surface templates sequentially according to the sequence from the bottom layer to the upper layer, and carrying out one-to-one correspondence with the layering sequence numbers, and then cutting the 50 water facing surface templates according to the design size.
Step 2, obtaining 50 back surface templates of a back surface forming die according to the method of the step 1;
step 3, laying plain prepreg cloth with the thickness of 0.25mm on the molded surface of the upstream surface molding die, putting a corresponding numbered upstream surface template, cutting off redundant prepreg cloth by taking the following edges, leading edges and blade tip sizes of the upstream surface template as references, turning over one side of the prepreg cloth, which is close to the blade root, towards one side, which is far away from the center surface of the blade, and taking out the upstream surface template with the number of 1 to finish the layering of the upstream surface layer; two unidirectional prepregs (with the thickness of 0.13 mm) with the thickness of 0.13mm are paved on the plain prepreg of the upstream surface layer, then a upstream surface template with the number of 2 is put on the unidirectional prepregs, more unidirectional prepregs are cut off based on the sizes of the trailing edge, the leading edge and the blade tip of the upstream surface template with the number of 2, one side, close to the blade root, of the prepreg is turned towards one side far from the center surface of the blade, and the upstream surface template with the number of 2 is taken off, so that the back surface layer paving is completed. And by analogy, alternately laying plain prepreg cloth and unidirectional prepreg cloth, and finally finishing all the layers of the upstream surface forming die to obtain the upstream surface preform with the first flanging.
And 4, layering the blade back surface die according to the step 3 to obtain a back surface preformed body with a second flanging.
And 5, oppositely jointing the upstream surface die and the downstream surface die after the layering in the step 3 and the step 4, inserting a locating pin, ensuring that dislocation does not occur when the two dies are jointed, enabling the steps formed by the oppositely jointing of the two dies to be within the range of 0.5mm-1.5mm, filling the material shortage part by using prepreg cloth, and simultaneously integrally coating the blade preformed body by using plain prepreg cloth to improve the apparent quality and performance of the blade, and finally closing the upper cover plate of the die. The blade forming die is locked by using bolts and nuts, the blade forming die is repaired according to the apparent mass of the blade after the die is disassembled, the blade is pre-pressed according to the method, after the die is disassembled, the surface of the blade is free of excess materials and unfilled parts, the blade preformed body is obtained, the thickness of a first flanging of the blade preformed body is 1.7mm, and the thickness of a second flanging of the blade preformed body is 2.3mm.
And 6, winding the filaments on the profile surface of the hub die, and prepressing and solidifying to obtain the hub preform.
And 7, arranging the hub preforming body and 9 blade preforming bodies in a die, uniformly arranging the 9 blade preforming bodies radially by taking a hub central shaft as a center, enabling a first flanging of each blade to be in contact with the periphery of the hub, enabling a second flanging of each blade to be in contact with one side, far away from the hub, of a first flanging of an adjacent blade, vacuumizing and curing, wherein the curing temperature is 195 ℃, and removing the die after curing to obtain the rotor.
Example 2
Example 2 provides a method for forming a blade, and with reference to example 1, example 2 differs from example 1 in that: in the step 3, the bottom layer is laid by adopting unidirectional prepreg cloth, then plain prepreg cloth is laid, and then the plain prepreg cloth is laid alternately.
Example 3
Example 3 provides a method for preparing a rotor, example 3 is referred to in example 1, and example 3 differs from example 1 in that: the thickness of the first flange of the blade preform was 1.8mm and the thickness of the second flange of the blade preform was 2.4mm.
Example 4
Example 4 provides a method for preparing a rotor, example 4 is referred to in example 1, and example 4 differs from example 1 in that: the thickness of the first flange of the blade preform was 2.2mm and the thickness of the second flange of the blade preform was 2.8mm.
Comparative example 1
Comparative example 1 provides a rotor preparation method in which prepreg cloth is directly laid on the profiles of a water-facing surface forming die and a water-facing surface forming die, respectively.
Comparative example 2
Comparative example 2 provides a method of manufacturing a rotor, and comparative example 2 differs from example 1 in that a plain prepreg cloth ply is used in each of comparative example 2, with reference to example 1.
Comparative example 3
Comparative example 3 provides a method of manufacturing a rotor, and comparative example 3 differs from example 1 in that comparative example 3 uses unidirectional prepreg layups.
Comparative example 4
Comparative example 4 provides a method of manufacturing a rotor, referring to example 1, comparative example 4 differs from example 1 in that the first and second rims of each blade are connected to the outer circumference of the hub.
Comparative example 5
Comparative example 5 provides a method of manufacturing a rotor, referring to example 1, comparative example 5 differs from example 1 in that the thickness of the first flange is 2.3mm and the thickness of the second flange is 1.7mm.
The molded blades of examples 1 to 4 and comparative examples 1 to 5 were subjected to profile, rigidity, strength, fatigue and weight testing, specifically:
the contour degree detection method comprises the following steps: the appearance of the rotor is scanned by adopting a flexible joint arm, a three-dimensional point cloud picture of the rotor is obtained, the three-dimensional point cloud picture is compared with a theoretical model, and the deviation degree is obtained, the greater the deviation degree is, the worse the profile degree is, the smaller the deviation degree is, and the better the profile degree is.
The rigidity detection method comprises the following steps: at the position of R=150mm of the rotor blade surface, according to 900N-1200N-1500N-10 min-1500N-100N of the load, after each stage of load is stable, observing the displacement; the larger the displacement amount, the lower the rigidity.
The intensity detection method comprises the following steps: loading the blade on a hub, arranging 6 measuring points on the blade surface and the blade back, sequentially loading 900N-1200N-1500N-1800N-2100N-2400N-2700N-3000N loads, wherein the first 7 loads are kept for 3s, the loads are kept for 3000N for 10min, in the load loading process, simultaneously measuring the surface strain of the blade and the displacement of the middle part of the blade tip, unloading to zero, and measuring the strain and the displacement of the middle part of the blade tip again; the larger the displacement amount, the larger the strain amount, indicating lower strength of the blade.
The fatigue detection method comprises the following steps: and loading to 2700N step by step, repeatedly and alternately loading linearly between 2430N and 2970N with the frequency of 20HZ, circulating 165000 times, recording whether abnormal sound exists in the circulating process, and observing whether cracks exist by using an electron microscope after the circulating is finished.
Rotor torque strength test: applying 100N-900N-1200N-1500N to the rotor, loading the rotor to the maximum load of 15KN for 10min in a guaranteed load mode, and unloading the rotor to zero in a gradient guaranteed load mode for 20 min; observing whether cracks exist at the joint of the blade and the hub by adopting an electron microscope; if a crack is observed at the joint of the blade and the hub, the joint strength of the rotor blade and the hub is low, the performance is poor, and otherwise, the joint strength is high, and the performance is good.
Weight deviation: the difference between the theoretical weight and the actual weight of the blade.
Limit rotation speed: placing the rotor in water to rotate at the rotating speeds of 150000r/min, 180000r/min, 210000r/min, 240000r/min, 270000r/min, 300000r/min, 330000r/min and 360000r/min respectively, detecting the internal mass by adopting an ultrasonic detector after each rotation, observing whether layering and debonding phenomena exist or not, observing the apparent mass by adopting a microscope, and observing whether cracks exist or not; the rotating speed of the rotor with layering debonding or cracks is the limit rotating speed; the larger the limit rotation speed, the better the performance of the rotor.
The results of the above-mentioned outer profile, rigidity, weight, strength and fatigue properties are shown in table 1.
TABLE 1
TABLE 2
From the data in tables 1 and 2, it can be seen that:
the blades prepared in examples 1 to 4 had a profile of 92.9 to 93.8%, a weight deviation of 2.0 to 3.2g, a displacement of 0.68 to 0.74mm in the stiffness test, no abnormal sound or crack in the fatigue test, and strains and displacements of 182 to 190. Mu.. Epsilon. And 0.86 to 1.05mm in the strength test, respectively. The rotors prepared in examples 1 to 5 had no cracks in the torque strength test, a service life of 15 to 20 years, and a limit rotation speed of 270000 to 330000r/min.
The blade prepared in comparative example 1 had a profile of 75%, a weight deviation of 15.8g, a displacement of 0.71mm in the stiffness test, no abnormal sound or crack in the fatigue test, and strains and displacements of 183. Mu.. Epsilon. And 0.94mm in the strength test, respectively. The profile of the blade prepared in comparative example 1 was lower than those of examples 1 to 4 of the present invention, because the blade was prepared by a method of directly laying prepreg on the profiles of the upstream surface forming die and the downstream surface forming die. The rotor prepared in comparative example 1 had no cracks in the torque strength test, and was unable to be put into service because of the unsatisfactory profile, which resulted in a loud noise when used underwater, and the lifetime was 0.
The blades prepared in comparative examples 2 and 3 had a profile of 92.6 to 93.5%, a weight deviation of 4 to 5g, a displacement of 0.58 to 1.08mm in the stiffness test, no abnormal sound or crack in comparative example 2 in the fatigue test, an abnormal sound or crack in comparative example 3, and strains and displacements of 160 to 195. Mu.. Epsilon. And 0.67 to 1.25mm in the strength test, respectively. The abnormal sound and crack occurred in comparative example 2 due to insufficient laying strength using plain prepreg cloth. In the torque strength test, the rotors prepared in comparative example 2 and comparative example 3 were crack-free in comparative example 2 and 2mm long in comparative example 3, because comparative example 3 was laid with unidirectional prepreg cloth, resulting in a service life of comparative example 3 of only 5 years and a limit rotation speed of only 180000r/min.
In comparative example 4, the first flange and the second flange were both connected to the outer periphery of the hub, the profile of the prepared blade was 93.0%, the weight deviation was 4.5g, the displacement in the stiffness test was 1.78mm, the abnormal sound in the fatigue test was cracked, and the strain and the displacement in the strength test were 5. Mu.. Epsilon. And 1.85mm, respectively. The stiffness and fatigue properties of the blades prepared in comparative example 4 are inferior to those of the blades prepared in examples 1 to 4 of the present invention, because the prepreg cloth is directly laid on the surfaces of the upstream surface forming die and the downstream surface forming die to prepare the blades. The rotor prepared in comparative example 4 had 3mm long cracks in the torque strength test, the service life was 6 years, and the limit rotation speed was 210000r/min.
The blade prepared in comparative example 5 had a profile of 93.9%, a weight deviation of 5.5g, a displacement of 0.75mm in the stiffness test, no abnormal sound or crack in the fatigue test, and strains and displacements of 185. Mu.. Epsilon. And 0.95mm in the strength test, respectively. The rotor prepared in comparative example 5 had cracks in the torque strength test for 9min, the service life was 10 years, the limit rotation speed was 240000r/min, and the torque strength of comparative example 5 was inferior to that of examples 1 to 4 of the present invention because the thickness of the first burring was greater than that of the second burring.
The invention provides a preparation method, a forming die and a preparation method of a rotor of a blade preform, wherein a blade root of the blade preform is provided with a first flanging for connecting with a rotor hub preform and a second flanging for connecting with a first flanging of an adjacent blade, so that the debonding risk of the blade and the rotor hub is reduced, the service life is prolonged, and the limit revolution is improved; and simultaneously, the connection strength of the blade and the hub is also provided. According to the structural characteristics of variable thickness and variable curvature of the blade and the stress characteristic of rotation under water, the profile of the upstream surface forming die and the profile of the downstream surface forming die of the blade are formed by periodically decreasing the layers, the upstream surface template is used as the basis of the profile layer of the upstream surface forming die, and the downstream surface template is used as the basis of the profile layer of the downstream surface forming die, so that accurate size detection can be accurately carried out on each layer of the layer, the decrease of the size of the layer is ensured to be matched with the target size of the blade, the outer profile of the blade is ensured, the weight deviation is small, the noise is low when the blade is applied in water, and the dynamic balance of rotation can be ensured; the formed blade does not need to be machined, so that the product performance is ensured, and the production period of the product is shortened. The blade prepared by the invention has the advantages of 92.9-93.8% of profile, good profile, 2.0-3.2g of weight deviation, high weight precision, 0.68-0.74mm of displacement in stiffness test, no abnormal sound or crack in fatigue test, 182-190 mu epsilon of strain and 0.86-1.05mm of displacement in strength test, and excellent stiffness, strength and fatigue performance; the rotor prepared by the method has no cracks in the torque strength test, the service life is 15-20 years, the limit rotating speed is 270000-330000r/min, the connection strength of the blades and the hub of the rotor is high, and the debonding risk of the blades and the hub is reduced.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. It is therefore intended that the following claims be interpreted as including the preferred embodiments and all such alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the spirit or scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims and the equivalents thereof, the present application is intended to cover such modifications and variations.
Claims (10)
1. A method of making a blade preform, the method comprising:
obtaining an upstream surface preform and a downstream surface preform; the blade root of the upstream surface preformed body is provided with a first flanging far away from the central surface of the blade, and the blade root of the downstream surface preformed body is provided with a second flanging far away from the central surface of the blade;
closing the upstream surface preformed body and the downstream surface preformed body, and performing pre-curing to obtain a blade preformed body with a first flanging and a second flanging;
the blade preforms are connected with the periphery of a hub of the rotor, the blade preforms are radially arranged with the central axis of the hub as the center, the first flanges of the blade preforms are connected with the periphery of the hub preform, and the second flanges of the blade preforms are connected with one side, away from the central axis of the hub, of the adjacent first flanges of the blade preforms.
2. The method of claim 1, wherein the thickness of the first flange is less than the thickness of the second flange; the second flange of each blade preform is adapted to contact the blade root of an adjacent blade preform.
3. A method of producing a vane preform as claimed in claim 2, wherein the thickness of the first flange is 1-2mm and the thickness of the second flange is 1.2-3mm.
4. A method of preparing a blade preform according to claim 1, wherein the length of the first turn along the circumferential direction of the hub does not exceed the length of the second turn along the circumferential direction of the hub.
5. A method of producing a blade preform according to any one of claims 1 to 4, wherein the obtaining of the upstream-side preform and the downstream-side preform comprises:
obtaining a plurality of upstream surface templates and a plurality of downstream surface templates, wherein the upstream surface templates are matched with the sizes of the to-be-paved layers of a plurality of upstream surfaces of a downstream surface forming die one by one; the back surface templates are matched with the sizes of the to-be-paved layers of the back surface surfaces of the back surface forming die one by one;
the prepreg cloth which is matched with the following edges, the guide edges and the blade tip sizes of the upstream surface templates one by one is paved on the surface of the upstream surface forming die in sequence from the bottom layer to the upper layer, and in each layer of paving, one side of the prepreg cloth, which is close to the blade root, is turned over in the direction away from the central surface of the blade so as to form a upstream surface preformed body with a first flanging;
and (3) laying prepreg cloth matched with the following edges, the guide edges and the blade tip sizes of the plurality of back surface templates one by one on the surface of the back surface forming die in sequence from the bottom layer to the upper layer, wherein in each layer of laying, one side of the prepreg cloth, which is close to the blade root, is turned over in a direction away from the central surface of the blade so as to form a back surface preformed body with a second flanging.
6. The method of producing a blade preform according to claim 5, wherein the thickness of the template is 0.3-0.5mm.
7. The method of producing a blade preform according to claim 5, wherein the prepreg cloth includes plain cloth and unidirectional cloth, and the ply of the plain cloth and the ply of the unidirectional cloth are alternately arranged.
8. A method of preparing a blade preform according to claim 7, wherein each ply has a thickness of 0.23-0.26mm; the distance between the edges of two adjacent layers is less than or equal to 5mm.
9. A forming die for producing the blade preform of any one of claims 1-8, wherein the forming die comprises an upstream face forming die having a profile matching the upstream face preform of any one of claims 1-8 and a downstream face forming die having a profile matching the downstream face preform of any one of claims 1-8.
10. A method of making a rotor using the blade preform of any one of claims 1-8, the method comprising:
obtaining a hub preform;
a plurality of first flanges of the blade pre-forms according to any one of claims 1-8 are contacted with the periphery of the hub pre-form, and second flanges of each blade pre-form are arranged on one side, far away from the central axis of the hub pre-form, of the first flanges of the adjacent blade pre-forms, and pressurization curing molding is carried out, so that a rotor is obtained.
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