Patent Application
20120270006
This invention relates to a composite flange element, and particularly but not exclusively relates to a composite flange element for a turbomachine component.
Where two components are to be connected, it is conventional to provide each component with a flange which abuts with the opposing flange and provides a means for connecting the two components. In addition, the flanges may also provide additional strength and stiffness to the components.
As shown in
The component 2 may be a casing component of a turbomachine. Conventionally, such a casing component would be manufactured from a metal, such as a titanium or a nickel alloy. Advantageously, metallic components usually have near homogeneous material properties irrespective of the component shape and method of manufacture.
The same can not be said for composite materials, particularly fibre reinforced organic matrix composites, which are highly heterogeneous. The properties of these materials depend on the local fibre orientation and the strength and stiffness of the material may vary greatly between regions of the component. It is however desirable to use such composite materials since they are generally lighter than metallic materials and may be cheaper than high-strength low-density metals, such as titanium. Furthermore, particular directionality of strength can be tuned by appropriate selection of ply material and orientation.
A composite component may be designed to ensure that it has the desired properties by selectively aligning the fibres in the composite material with the directions of anticipated loads. This may be performed on a local scale such that localised regions of the component are provided with appropriately oriented fibres to produce the desired properties for that region.
For example casing components are often designed to withstand pressure vessel loads, to provide roundness stability, and to guarantee containment of a blade in the event of a blade-off. The main body of the component therefore has to have good hoop and axial strength and stiffness.
The flange portion of the component must maintain its shape under asymmetric loading to prevent leakage from the interface between the two components.
The present invention provides a composite flange having a ply layup which provides desirable properties for the flange and which enables the metal flange to be replaced by a composite material.
According to the invention there is provided a composite flange element as set out in the claims.
The present invention provides a composite flange having a ply layup which provides desirable properties for the flange and which enables the metal flange to be replaced by a composite material. This has benefits to weight, cost and durability of the components.
The present invention has particular application in turbomachines, particularly for casing components.
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
The composite flange element is shown abutted to a second flange element 16. The second flange element 16 may be a metal flange element, such as that shown in
The hole 22 in the composite flange element 10 is sufficiently larger in diameter than the bolt 26 to prevent the bolt 26 from contacting the composite material under conditions such as thermal expansion, bolt misalignment, etc. Such contact may cause damage to the composite material. Care should also be taken to avoid snagging the thread of the bolt 26 on the composite material as the bolt is threaded through the hole. The bolt is provided with a washer 26 to spread the clamping load of the bolt and to avoid crush type failures at the edge of the hole. Alternatively, a metallic annular washer may be provided with a series of holes passing therethrough, which correspond to the holes around the circumference of the composite flange element 10. Such a configuration would spread the clamping load of the bolts equally around the composite flange element 10 and could also be made thicker to provide additional stiffness to the flange portion 14, if required. The annular washer may be formed from two or more arcuate sections to allow the washer to be fitted more easily. For example, the washer may be formed from two semicircular sections. As shown in
In other embodiments of the invention, the load-spreading feature may be provided by one or more additional layers of material provided outward of the composite plies. These layers may be formed of glass fibre composite material, metallic material, or of polymer material. If more than one such layer is provided, they may be of the same or of different materials. Particularly suitable polymers would be those having a relatively low coefficient of friction, such as PTFE, or such as glass fibre strip impregnated with PTFE and sold under the registered trade mark “Vespel”.
The inner and outer corners where the portion 12 of the component meets the flange portion 14 may be provided with discontinuous fibres 28 in order to reduce the stress in this region of the composite flange element. These regions are resin-rich and it is difficult to provide structural fibres here. The discontinuous fibres may be provided by packing a filler preform into the mould or by using chopped fibre. The discontinuous fibres may be provided in one or more of the positions marked 28 in
Alternatively, these resin-rich regions may be removed by modifying the geometry of the composite flange element 10. Further still, the inner and outer corners may be manufactured so that they are over-sized and subsequently machined back to the desired shape. This would allow structural fibres to be used in these regions; however, the machining process would result in the fibres becoming discontinuous.
The ply layup of the composite flange element 10 will now be described with reference to
The ply layup comprises one or more first plies 30 indicated by the cross-hatched portions, one or more second plies 32 indicated by the striped portions and one or more third plies 34 indicated by the blank portions. The ply layup further comprises resin-rich areas 36, ply drops 38 and ply butts 40. The ply drops 38 are located where the first plies 30 terminate and the ply butts are located where the second plies 32 abut the third plies 34.
The first plies 30 extend over both the cylindrical portion 12 of the component and the flange portion 14. The second plies 32 extend over the flange portion 14 and one or more of the second plies 32 may optionally extend partially over the cylindrical portion 12 of the component. However, where the second plies 32 extend over the cylindrical portion 12 of the component, this is to a lesser extent than the first plies 30. The third plies 34 extend over the cylindrical portion 12 of the component and one or more of the third plies 34 may optionally extend partially over the flange portion 14. However, where the third plies 34 extend over the flange portion 14, this is again to a lesser extent than the first plies 30.
The outermost layers of the first plies 30 cover the entire component. Inner layers of the first plies 30 may be curtailed to reduce weight. The outermost layers of the first plies 30 are generally the surfaces layers of the component, however additional layers may be added post-curing, such as internal liners, or surface protection layers such as anti-erosion material, or paint.
The specific fibre orientation, structure and method of construction of the first, second and third plies will now be described with reference to
The first plies 30 may be formed by braiding, which is a specific known method of interleaving tows or fibres. By using braiding, the first plies are formed as tubes which can follow the flange portion geometry without having a join or fold. Alternatively, the first plies may be formed by other methods of interleaving and interlocking, such as weaving or 3D weaving, knotting, felting, knitting or tatting. Filament winding is a form of 1.5D weaving, which may also be used.
The second plies may be formed by tailored fibre placement. This is where tows of fibres are oriented in the desired directions and then stitched into place onto a backing sheet 45.
Alternatively, several layers of standard fabric, as shown in
As shown in
It is beneficial to provide a large number of darts so as to reduce wrinkling in the backing sheet 45. This may also be improved by using a lightweight material which can accommodate the draping required or by providing smaller darts between the fibres.
The circumferential fibres 44 may then be stitched onto the flange portion 14. Alternatively, filament winding or tape laying may be used to apply such a layer of fibres.
The third plies 34 extend over the cylindrical portion 12 of the component and are required to provide the component with stiffness in both circumferential and axial directions. The third plies 34 may be a single layer woven fabric such as a 5 harness satin weave, which has not too much crimp but is interwoven enough to hold together during manufacturing. This is preferably wrapped around the barrel several times, so that the start and finish line of weakness is minimised.
Alternatively a multi-layer fabric may be chosen, such as a 3 or 4 ply Non Crimp Fabric (NCF). In this material, the 0 and 90 degree fibres are virtually un-crimped, and held in place by very light interwoven fibres. The advantage of this material is that the material is inherently stiffer, because the crimping is eliminated, and layup is also quicker as several thicknesses of material are handled in each ply. However, in contrast to a single layer fabric, the join line of weakness is more pronounced and can only be minimised over several blockings of layup. In addition, the material is less easily draped, making it difficult to shape it around even a part of the flange portion 14. This problem may be solved by using a 3D woven fabric, but such a fabric would not be as inherently stiff. However, a 3D woven material may be suited to use in a containment casing, where deflection under impact and spreading out the area of impact damage is desirable.
Possibly the most effective pre-forming method to obtain hoop and axial stiffness simultaneously, and avoid the join problem, is to use 2½ D braiding. This is like 2D braiding, in that it creates a tube of material that is wrapped over a mandrel. The difference is that axial fibres are also added, so that the tube is no longer “stretchy” (cannot be made to grow or shrink in diameter), as the axial fibres constrain it. In this way, the axial fibres constrain the shape so that the act of braiding creates a given shape, rather than a shape that can change by shearing of the fibres. Obviously the axial fibres are needed to provide axial stiffness to the cylindrical portion 12 of the component. The relative proportion of axial fibres can be chosen. The hoop stiffness is provided by the other fibres, which instead of being loosely braided in a very open form at a nominal 45°, they are packed at as shallow an angle as possible. In this way, they are very nearly hoop aligned, closely spaced, and braided straight into position, so the alignment and packing tolerance is good.
If hoop stiffness needs further enhancement, filament winding may be used. This may be in combination with UD or with NCF or woven fabric with a higher tow number in the axial direction. This also has the benefit of minimising the join line problem.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1106794.9 | Apr 2011 | GB | national |
