Simulation of shaped geometric error for variable curvature composite propeller blade

doi:10.3785/j.issn.1008-973X.2025.06.019

Journal of ZheJiang University (Engineering Science)

2025, Vol. 59

Issue (6): 1284-1292 DOI: 10.3785/j.issn.1008-973X.2025.06.019

Simulation of shaped geometric error for variable curvature composite propeller blade

Yongjie BAO1(

),Leqiang ZHANG1,Zhen LIU1,Xiukun JI2,Yuxing YANG1,*(

)

1. College of Marine Engineering, Dalian Maritime University, Dalian 116026, China
2. College of Naval Architecture and Ocean Engineering, Dalian Maritime University, Dalian 116026, China

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Abstract

There are shaped geometric error in the prepreg forming process due to the variable curvature, variable thickness and laminated characteristics of composite propeller blades. In order to clarify the influence of blade curvature and ply strain on the geometric error of prepreg forming, a numerical model of the prepreg placement process inside the blade mold was established by obtaining point cloud data through three-dimensional scanning of the blade layer. The finite element simulation of the prepreg placement process was carried out. The effectiveness of the proposed laying simulation model was verified by comparing the results of layer strain tests with the simulation results. An evaluation method based on the accumulation of deformation error in the normal vector direction was proposed, and the interlayer errors from the laying test results and the simulation results were extracted. The interlayer errors were used to analyze the shaped geometric error of the blade with considering the blade curvature characteristics. Results showed that the lateral difference of the shaped geometric error between the simulation and the experiment was about 10.18%, and the longitudinal difference was about 14.22%. The distribution pattern of shaped geometric error of the blade was consistent with that of the strain distribution, and the influence of the fluctuation of the curvature on the shaped geometric error was greater than that caused by the difference in the curvature itself. The distribution of the shaped geometric error tended to be V-shaped as the number of layers increased, and the influence of curvature fluctuation became more and more obvious.

Key words： shaped geometric error prepreg ply composite material propeller blade normal vector deformation

Received: 10 April 2024 Published: 30 May 2025

CLC:

TB 332

Fund: 国家自然科学基金资助项目（52301359）；辽宁省应用基础研究资助项目（2022JH2，101300221）.

Corresponding Authors: Yuxing YANG E-mail: yongjie@dlmu.edu.cn;yangyuxing@dlmu.edu.cn

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Cite this article:

Yongjie BAO,Leqiang ZHANG,Zhen LIU,Xiukun JI,Yuxing YANG. Simulation of shaped geometric error for variable curvature composite propeller blade. Journal of ZheJiang University (Engineering Science), 2025, 59(6): 1284-1292.

URL:

https://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2025.06.019 OR https://www.zjujournals.com/eng/Y2025/V59/I6/1284

变曲率复合材料螺旋桨叶的赋形几何误差仿真

复合材料螺旋桨叶的变曲率、变厚度和叠层特征会导致预浸料赋形过程中存在几何误差. 为了明确叶片曲率与铺层应变对赋形几何误差的影响规律，通过对桨叶铺层进行三维扫描获取点云数据，建立桨叶模具预浸料铺放过程的数值模型，对预浸料铺放过程进行有限元模拟. 通过对比铺层应变试验和仿真结果验证所提出的铺放仿真模型的有效性. 提出基于法向量方向变形误差累积的评价方法，对铺层试验和仿真结果进行层间误差提取，并结合叶片曲率特征分析桨叶赋形误差. 结果表明，仿真与试验的赋形几何误差的横向偏差约为10.18%、纵向偏差约为14.22%. 桨叶赋形几何误差分布形式与其铺放过程应变分布规律一致，曲率的波动性对赋形几何误差的影响大于曲率自身差异性的影响. 赋形几何误差分布随铺层数量增加趋于V型特征，且受曲率波动性的影响越来越明显.

关键词： 赋形几何误差, 预浸料铺层, 复合材料, 螺旋桨叶, 法向量变形

Tab.1 Properties of T300 unidirectional carbon fiber prepreg^[4]

Fig.1 Size of single-layer prepreg test piece

Fig.2 Finite element model of lay-up of prepreg for composite materials

Fig.3 Strain test of characteristic point during lay-up process of prepreg

Fig.4 Prepreg layer of composite propeller blade

Fig.5 Three-dimensional scanning test of composite propeller blade prepreg lay-up

Fig.6 Unified coordinate system of shaped geometric error comparison of prepreg layer

Fig.7 Shaped geometric error analysis feature points of composite propeller blade lay-up

Fig.8 Normal vector orientation deformation evaluation method of prepreg lay-up error analysis

Fig.9 Cumulative error in laying process of composite propeller blade prepreg

Fig.10 Floating of feature points in laying process of composite propeller blade prepreg

Fig.11 Strain at characteristic points during prepreg lay-up

Fig.12 Distribution law of shaped geometric error, strain and blade curvature


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