Manufacturing of a draft element of a helicopter control system thrust using volume-reinforced woven carbon fiber preforms

Donetskiy K.I., Karavaev R.Y., Bystrikova D.V., Melnikov D.A., Gracheva A.D., Gorodilova N.A.
Donetskiy K.I., Karavaev R.Y., Bystrikova D.V., Melnikov D.A., Gracheva A.D., Gorodilova N.A. Manufacturing of a draft element of a helicopter control system thrust using volume-reinforced woven carbon fiber preforms // Proceedings of VIAM. 2025. No. 8. DOI: 10.18577/2307-6046-2025-0-8-112-122. URL: https://test.viam.ru/en/journal/2025/8/10
Keywords
volumetric reinforcing braided preform, vacuum infusion, binder, pressure impregnation, carbon fiber, shaft, transmission
Abstract

The technology for manufacturing a blank of a thrust element of a helicopter control system using volumetric-reinforcing braided preforms and a melt epoxy binder of Russian production has been developed. The optimal mode for the process of impregnation under pressure and the manufacture of a low-porosity material without delamination and defects in the zone of a metal embedded element – carbon fiber has been determined. The technology is promising for aviation, shipbuilding, mechanical engineering in the manufacture of complex structures such as transmission shafts, control system rods or specialized drives.

Reference list
  1. Kablov E.N. New Generation Materials and Technologies for Their Digital Processing. Herald of the Russian Academy of Sciences, 2020, vol. 90, no. 2, pp. 225–228.
  2. Onishchenko G.G., Kablov E.N., Ivanov V.V. Scientific and technological development of Russia in the context of achieving national goals: problems and solutions. Innovatsii, 2020, no. 6 (260), pp. 3–16.
  3. Kablov E.N., Antipov V.V. The role of new generation materials in ensuring the technological sovereignty of the Russian Federation. Vestnik Rossiyskoy akademii nauk, 2023, vol. 93, no. 10, pp. 907–916.
  4. Mikhailin Yu.A. Fibrous polymer composite materials in engineering. St. Petersburg: Scientific foundations and technologies, 2013, 720 p.
  5. Raskutin A.E. Russian polymer composite materials of new generation, their exploitation and implementation in advanced developed constructions. Aviacionnye materialy i tehnologii, 2017, no. S, pp. 349–367. DOI: 10.18577/2071-9140-2017-0-S-349-367.
  6. Irving P.E., Soutis C. Polymer composites in the aerospace industry. Sawston, Cambridge: Woodhead Publishing, 2019, 536 р.
  7. Basharov E.A., Vagin A.Yu. Analysis of the use of composite materials in the design of helicopter airframes. Trudy MAI, 2017, no. 92, pp. 1–33.
  8. Liang R., Xu F., Zou Z. et al. Mechanical properties analysis and experimental study of double-lap mechanically connected carbon fiber drive shafts. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2024, vol. 46, p. 467. DOI: 10.1007/s40430-024-05049-9.
  9. Raushan R., Dhande K.K., Jamadar N.I. Modal analysis of carbon fiber reinforced polyamide 66 drive shaft using analytical and finite element approach. The International Journal on Interactive Design and Manufacturing, 2025, vol. 19, pp. 2801–2816. DOI: 10.1007/s12008-024-01854-7.
  10. Carbon fiber drive shaft: pat. US4089190A; appl. 14.04.76; publ. 16.05.78.
  11. Helicopter transmission. Avia.pro: information agency. Available at: http://avia.pro/blog/transmissiya-vertoleta (accessed: June 10, 2025).
  12. Timoshkov P.N., Hrulkov A.V., Grigoreva L.N. Сarbon fiber transmission shaft. Materials and technology (review). Trudy VIAM, 2020, no. 8 (90), paper no. 05. Available at: http://www.viam-works.ru (accessed: June 11, 2025). DOI: 10.18577/2307-6046-2020-0-8-46-53.
  13. Composite tube for torque and/or load transmissions and related methods: pat. US 2014221110, appl. 05.02.14, publ. 07.08.14.
  14. Carey J.P. Handbook of Advances in Braided Composite Materials: Theory, Production, Testing and Application. Woodhead Publishing; Elsevier, 2017, pp. 3–6.
  15. Belinis P.G., Donetskiy K.I., Lukyanenko Yu.V., Rogozhnikov V.N., Mayer Yu., Bystrikova D.V. Volume reinforcing solid-woven preforms for manufacturing of polymer composite materials (review). Aviacionnye materialy i tehnologii, 2019, no. 4 (57), pp. 18–26. DOI: 10.18577/2071-9140-2019-0-4-18-26.
  16. Dushin M.I., Hrulkov A.V., Muhametov R.R., Chursova L.V. Features of manufacturing of products from PCM impregnation method under pressure. Aviacionnye materialy i tehnologii, 2012, no. 1, pp. 18–26.
  17. Doneckiy K.I., Karavaev R.Yu., Raskutin A.E., Panina N.N. Properties of carbon fiber and fiberglass on the basis of braiding preforms. Aviacionnye materialy i tehnologii, 2016, no. 4 (45), pp. 54–59. DOI: 10.18577/2071-9140-2016-0-4-54-59.
  18. Donetskiy K.I., Usacheva M.N., Khrulkov A.V. Infusion methods for the manufacture of polymer composite materials (review). Part 1. Trudy VIAM, 2022, no. 6 (112), paper no. 06. Available at: http://www.viam-works.ru (accessed: June 11, 2025). DOI: 10.18577/2307-6046-2022-0-6-58-67.
  19. Mishkin S.I., Zhakova L.S., Klimenko O.N., Vasilchuk E.A. Research of influence of the contents resin in CFRP on their mechanical properties. Trudy VIAM, 2023, no. 2 (120), paper no. 07. Available at: http://www.viam-works.ru (accessed: June 12, 2025). DOI: 10.18577/2307-6046-2023-0-2-77-86.
  20. Panina N.N., Kim M.A., Gurevich Ya.M., Grigoriev M.M., Chursova L.V., Babin A.N. Binders for non-autoclave molding of products from polymer composite materials. Klei. Germetiki. Tehnologii, 2013, no. 10, pp. 18–27.
  21. Mukhametov R.R., Petrova A.P. Thermosetting binders for polymer composites (review). Aviacionnye materialy i tehnologii, 2019, no. 3 (56), pp. 48–58. DOI: 10.18577/2071-9140-2019-0-3-48-58.
  22. Resin composition, a fiber reinforced material having a partially impregnated resin and composites made therefrom: pat. US6139942; appl. 06.02.97; publ. 31.10.00.
  23. Varvani-Farahani A. Composite materials: characterization, fabrication and application-research challenges and directions. Applied Composite Materials, 2010, vol. 17, is. 2, pp. 63–67.
  24. Donetskiy K.I., Karavaev R.Yu., Bystrikova D.V., Mishchun M.I. Properties of carbon fiber based on a biaxial volumetric-reinforcing woven preform for the manufacture of tubular structure elements. Konstruktsii iz kompozitsionnykh materialov, 2022, no. 2 (166), рр. 8–14.
  25. Goncharov V.A., Usacheva M.N., Khrulkov A.V. Features of the structure and reinforcement transmission shafts made of polymer composite materials (review). Trudy VIAM, 2021, no. 1 (95), paper no. 9. Available at: http://www.viam-works.ru (accessed: June 15, 2025). DOI: 10.18577/2307-6046-2021-0-1-85-96.