Automatic fiber placement assembly and method for forming component

Abstract

An automatic fiber placement assembly forms a component by placing individual or multiple layers of fiber bundles. The automatic fiber placement assembly includes a cutter assembly defining a cut shape. The back plate is spaced from the first cutter assembly, and the cutter assembly can cut the fiber bundle against the back plate. The fiber bundle defines a longitudinal axis and is fed in a feed direction between the first cutter assembly and the backing plate. The cutter head assembly is rotatable and movable to change the orientation of the cutter assembly so as to define different cutting shapes that are non-orthogonal to the longitudinal axis.

Description

Technical Field

[0001] The present disclosure relates generally to automated fiber placement assemblies for forming components or composite parts, and in particular, to tools for cutting fibers during fiber placement during the formation of a component. Background Art

[0002] Many components, such as components for turbine engines, are made of composite materials, which may include a fiber-reinforced matrix and exhibit a high strength-to-weight ratio. Composite materials are used in a variety of applications due to the high strength-to-weight ratio and formability into relatively complex shapes. Components made of composite materials may be used in aerospace applications, for example, to form at least a portion of a fuselage and / or wing, rudder, manifold, turbine engine, airfoil, blade, vane, or other component of an aircraft. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0004] Figure 1 is a schematic cross-sectional view of a turbine engine according to an exemplary aspect of the present disclosure.

[0005] Figure 2 is suitable for use in accordance with exemplary aspects of the present disclosure Figure 1 A schematic perspective view of a composite airfoil assembly and disk assembly for use within a turbine engine.

[0006] Figure 3 is a schematic perspective view of an automated fiber placement assembly with a cutter head assembly according to an exemplary aspect of the present disclosure.

[0007] Figure 4 According to an exemplary aspect of the present disclosure, a set of cutter heads is provided. Figure 3 An enlarged schematic diagram of the cutter head assembly.

[0008] According to an exemplary aspect of the present disclosure, Figure 5 Includes multiple sets of exemplary fiber bundles, showing Figure 3 and Figure 4 The cutter head assembly is capable of a variety of cutting shapes within the range.

[0009] Figure 6 is a schematic perspective view of another automated fiber placement assembly having two cutter head assemblies configured to cut opposing ends of a fiber bundle according to an exemplary aspect of the present disclosure.

[0010] Figure 7 is a schematic perspective view of yet another automated fiber placement assembly having a laser cutter assembly according to an exemplary aspect of the present disclosure.

[0011] Figure 8 A flow chart depicting a method of forming a component for a turbine engine according to an exemplary aspect of the present disclosure is shown. DETAILED DESCRIPTION

[0012] Aspects disclosed herein relate to systems and methods for forming components, such as components for turbine engines, or any other component that can be formed in whole or in part by an automated fiber placement (AFP) assembly or machine. Automated fiber placement machines can be used to lay down successive layers of fiber bundles to build or add to a component. Components can include simple geometries, but are often complex and the application of overhanging bundle ends or fiber bundles is undesirable due to the complex shape of the component to be formed.

[0013] As described herein, an automated fiber placement assembly may be used to form a component or to apply a fiber bundle during the formation of a component, such as an engine component used in a turbine engine of an aircraft. Such an engine component may be an airfoil, such as an airfoil for a fan blade. It should be understood that the present disclosure may be similarly applied to other components of a turbine engine, such as a combustor liner or disk in a non-limiting example, as well as non-aircraft or non-engine components. Although described in terms of components of a turbine engine, it should be understood that the present disclosure may be applied to any component and need not be specific to a turbine engine or aircraft.

[0014] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter references to refer to features in the drawings. Like or similar reference numbers in the drawings and description have been used to refer to like or similar parts of the present disclosure.

[0015] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. In addition, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0016] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of each component.

[0017] As used herein, the term "upstream" refers to the direction opposite to the direction of fluid flow, while the term "downstream" refers to the direction in the same direction as the direction of fluid flow. The terms "front" or "frontward" mean in front of something, and "rear" or "rearward" mean behind something. For example, when used in relation to fluid flow, front / front may refer to upstream, and rear / rearward may refer to downstream.

[0018] The term "fluid" may be gas or liquid, or multiple phases.

[0019] Furthermore, as used herein, the term "radial" or "radially" refers to directions away from a common center. For example, in the overall context of a turbine engine, radial refers to directions along a ray extending between a central longitudinal axis of the engine and an outer periphery of the engine.

[0020] All directional references as may be used herein (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, transverse, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are used only for identification purposes to help the reader understand the present disclosure and do not create limitations, particularly limitations on the position, orientation, or use of the disclosed aspects described herein. Connection references (e.g., attachment, coupling, connection, and engagement) will be interpreted broadly and may include intermediate structural elements between sets of elements and relative movement between elements, unless otherwise indicated. Therefore, a connection reference does not necessarily mean that the two elements are directly connected and fixed relative to each other. The exemplary drawings are used for illustration purposes only, and the dimensions, positions, orders, and relative sizes reflected in the attached drawings may vary.

[0021] Unless the context clearly dictates otherwise, the singular forms "a," "an," and "the" include plural references. Also, as used herein, the term "set" or a "set of" elements may be any number of elements, including only one.

[0022] As used herein, the term "composite" refers to a component having two or more materials. A composite can be a combination of at least two or more metals, non-metals, or a combination of metal and non-metal elements or materials. Examples of composite materials can be, but are not limited to, polymer matrix composites (PMC), ceramic matrix composites (CMC), metal matrix composites (MMC), carbon fibers, polymer resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0023] As used herein, a "composite" component refers to a structure or component that includes any suitable composite material. A composite component, such as a composite airfoil, may include several layers or several layups of composite materials. The stiffness, material, and dimensions of the layers or layups may vary to form a composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0024] In addition, as used herein, "controller" or "controller module" may include a component that is constructed or adapted to provide instructions, control, operation or any form of communication to an operable component to affect its operation. The controller module may include any known processor, microcontroller or logic device, including but not limited to: field programmable gate array (FPGA), application specific integrated circuit (ASIC), full authority digital engine control (FADEC), proportional controller (P), proportional integral controller (PI), proportional differential controller (PD), proportional integral differential controller (PID controller), hardware accelerated logic controller (e.g., for encoding, decoding, transcoding, etc.), etc., or a combination thereof. Non-limiting examples of controller modules may be constructed or adapted to run, operate or otherwise execute program code to achieve an operation or functional result, including performing various methods, functions, processing tasks, calculations, comparisons, sensing or measurement values, etc., to enable or achieve the technical operations or operations described herein. The operation or functional result may be based on one or more inputs, stored data values, sensing or measurement values, true or false indications, etc. Although "program code" is described, non-limiting examples of operable or executable instruction sets may include routines, programs, objects, components, data structures, algorithms, etc., that have a technical effect of performing a specific task or implementing a specific abstract data type. In another non-limiting example, the controller module may also include a data storage component accessible by the processor, including a memory, whether it is a transient memory, a volatile or non-transient memory, or a non-volatile memory. Other non-limiting examples of memory may include random access memory (RAM), read-only memory (ROM), flash memory, or one or more different types of portable electronic memory, such as a disk, DVD, CD-ROM, flash drive, universal serial bus (USB) drive, etc., or any suitable combination of these types of memory. In one example, the program code may be stored in a memory in a machine-readable format accessible to the processor. In addition, the memory may store various data, data types, sensed or measured data values, inputs, generated or processed data, etc., that the processor may access when providing instructions, controls or operations to affect functions or operable results, as described herein.

[0025] In addition, as used herein, an element "electrically connected", "electrically coupled", "communicatively coupled" or "electrically communicates", and terms similar thereto, may include electrical transmission, wired or wireless transmission, or signal transmission, reception or communication to or from such connected or coupled elements. In addition, such electrical connection or coupling may include wired or wireless connection, or a combination thereof.

[0026] One or more layers of adhesive may be used to form or join the composite parts. The adhesive may include resins and phenolics, where the adhesive may be cured at elevated temperatures or by other hardening techniques.

[0027] As used herein, PMC refers to a class of materials. As an example, PMC materials are defined in part by prepregs, which are reinforcing materials pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). Non-limiting examples of processes for producing thermoplastic prepregs include: hot melt prepregs, in which a fiber reinforcement is pulled through a molten bath of resin; and powder prepregs, in which resin is deposited onto the fiber reinforcement, as a non-limiting example, electrostatically deposited onto the fiber reinforcement, and then adhered to the fibers, as a non-limiting example, in an oven or with the help of heated rollers. Prepregs can be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of each other to create several stacked layers that form a part.

[0028] Multilayer prepreg is stacked to the appropriate thickness and orientation of composite parts, and then resin is cured and solidified to provide fiber reinforced composite parts. The resin for PMC matrix material can be generally classified as thermosetting resin or thermoplastic resin. Thermoplastic resin is generally classified as a polymer that can be repeatedly softened and flowed when heated and can be hardened due to physical changes rather than chemical changes when fully cooled. The famous example category of thermoplastic resin includes nylon, thermoplastic polyester, polyaryletherketone and polycarbonate resin. The specific example of high-performance thermoplastic resin for aerospace applications has been envisioned to include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK) and polyphenylene sulfide (PPS). On the contrary, once fully cured into a hard rigid solid, thermosetting resin will not experience significant softening when heated, but thermally decomposes when fully heated. The famous example of thermosetting resin includes epoxy resin, bismaleimide (BMI) and polyimide resin.

[0029] Instead of using prepreg, in another non-limiting example, by using thermoplastic polymers, woven fabrics can be utilized. Woven fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg weaving architectures can be made in a similar manner. With this approach, the fiber volume of a part can be customized by specifying the relative concentrations of thermoplastic fibers and reinforcing fibers that have been woven or woven together. In addition, different types of reinforcing fibers can be woven or woven together at different concentrations to customize the properties of a part. For example, glass fibers, carbon fibers, and thermoplastic fibers can all be woven together at different concentrations to customize the properties of a part. Carbon fibers provide the strength of the system, glass fibers can be incorporated to enhance impact properties, which is a design feature of a part located near the engine inlet, and thermoplastic fibers provide bonding for the reinforcing fibers.

[0030] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite component. Typically, RTM includes applying a dry fiber or matrix material to a mold or cavity. The dry fiber or matrix material may include prepregs, woven materials, braided materials, or any combination thereof.

[0031] The resin may be pumped or otherwise provided to the mold or cavity to impregnate the dry fibers or matrix material. The combination of the impregnated fibers or matrix material and the resin is then cured and removed from the mold. The composite part may include a post-curing process when removed from the mold.

[0032] It is contemplated that RTM may be a vacuum assisted process. That is, the air in the cavity or mold may be removed and replaced with resin prior to heating or curing. It is further contemplated that placement of dry fiber or matrix material may be manual or automated.

[0033] The dry fiber or matrix material may be shaped to form the composite part or to guide the resin. Optionally, additional layers or reinforcements of a material different from the dry fiber or matrix material may also be included or added prior to heating or curing.

[0034] As used herein, CMC refers to a class of materials having reinforcing fibers in a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0035] Some examples of ceramic matrix materials may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included in the ceramic matrix.

[0036] In general, specific CMCs can be referred to as their fiber type / matrix type combination. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN is silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, etc. In other examples, CMCs can be composed of a matrix and reinforcing fibers comprising oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof. Aluminosilicates can include crystalline materials such as mullite (3Al2O3·2SiO2), as well as glassy aluminosilicates.

[0037] In certain non-limiting examples, the reinforcing fibers may be bundled and / or coated before being included in the ceramic matrix. For example, the fiber bundles may be formed into reinforcing tapes, such as unidirectional reinforcing tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with a slurry composition before or after forming the preform. The preform may then be subjected to heat treatment and subsequent chemical treatment to obtain a component formed of a CMC material having a predetermined chemical composition. For example, the preform may undergo curing or burnout to produce a high coke residue in the preform, and then be melt infiltrated with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform, and then be chemically infiltrated with silicon carbide. Additional steps may be taken to improve the densification of the preform, by injecting the preform with a liquid resin or polymer before or after chemical vapor infiltration, followed by a heat treatment step to fill the voids with silicon carbide. CMC materials as used herein may be formed using any known or later developed method including, but not limited to, melt infiltration, chemical vapor infiltration, polymer infiltration pyrolysis (PIP), or any combination thereof.

[0038] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcement materials), are particularly useful for higher temperature applications. In addition, these ceramic materials are lightweight compared to superalloys, yet still provide strength and durability to components made therefrom. As a result, such materials are currently being considered for use in many gas turbine components used in the higher temperature sections of gas turbine engines (such as airfoils (e.g., turbines and buckets), combustors, shrouds, and other components) that would benefit from the lighter weight and higher temperature capabilities that these materials can provide.

[0039] The inventors practiced in the manner described above (i.e., designing a system for manufacturing components and designing the system to have improved bundle fiber application and cutting). The system was used in designing and creating several different types of components (such as Figure 1 and Figure 2 Components used in the turbine engine shown) are used during.

[0040] Figure 1 is a schematic cross-sectional view of a turbine engine 10 for an aircraft. The turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending from a front portion 14 to an aft portion 16. The turbine engine 10 includes, in downstream serial flow relationship: a fan section 18 including a fan 20; a compressor section 22 including a supercharger or low pressure (LP) compressor 24 and a high pressure (HP) compressor 26; a combustion section 28 including a combustor 30; a turbine section 32 including an HP turbine 34 and an LP turbine 36; and an exhaust section 38.

[0041] The fan section 18 includes a fan case 40 surrounding the fan 20. The fan 20 includes a plurality of fan blades 42 radially arranged around the engine centerline 12. The HP compressor 26, the combustor 30, and the HP turbine 34 form an engine core 44 of the turbine engine 10, which generates combustion gases. The engine core 44 is surrounded by a core case 46, which may be coupled to the fan case 40.

[0042] An HP shaft or spool 48 disposed coaxially about the engine centerline 12 of the turbine engine 10 drivingly connects the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50 disposed coaxially about the engine centerline 12 of the turbine engine 10 within the larger diameter annular HP spool 48 drivingly connects the LP turbine 36 to the LP compressor 24 and the fan 20. The spools 48, 50 are rotatable about the engine centerline 12 and are coupled to a plurality of rotatable elements that may collectively define a rotor 51.

[0043] The LP compressor 24 and the HP compressor 26 each include a plurality of compressor stages 52, 54, wherein a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 to compress or pressurize a fluid flow through the stage. In a single compressor stage 52, 54, the plurality of compressor blades 56, 58 may be arranged in a ring and may extend radially outward from a blade platform to a blade tip relative to the engine centerline 12, with the corresponding static compressor vanes 60, 62 positioned upstream and adjacent to the rotating compressor blades 56, 58. Notably, Figure 1 The numbers of blades, buckets, and compressor stages shown in FIG. 5 are selected for illustration purposes only, and other numbers are possible.

[0044] Compressor blades 56, 58 for a stage of compressors 24, 26 may be mounted to (or integrated into) a disk 61 mounted to a corresponding one of the HP and LP spools 48, 50. Static compressor vanes 60, 62 for a stage of compressors 24, 26 may be mounted to the core housing 46 in a circumferential arrangement.

[0045] The HP turbine 34 and the LP turbine 36 each include a plurality of turbine stages 64, 66, wherein a set of turbine blades 68, 70 rotate relative to a corresponding set of static turbine vanes 72, 74 (also referred to as nozzles) to extract energy from a fluid flow passing through the stage. In a single turbine stage 64, 66, the plurality of turbine blades 68, 70 may be arranged in a ring and may extend radially outward relative to the engine centerline 12, while the corresponding static turbine vanes 72, 74 are positioned upstream and adjacent to the rotating turbine blades 68, 70. Notably, Figure 1 The number of blades, buckets, and turbine stages shown in FIG. 5 are selected for illustration purposes only, and other numbers are possible.

[0046] Turbine blades 68, 70 for a stage of turbines 34, 36 may be mounted to disks 71 mounted to respective ones of HP and LP spools 48, 50. Static turbine buckets 72, 74 for a stage of compressors 24, 26 may be mounted to core housing 46 in a circumferential arrangement.

[0047] Complementing the rotor portion, the stationary portion of the turbine engine 10, such as the stationary blades 60, 62, 72, 74 in the compressor section 22 and the turbine section 32, are also individually or collectively referred to as stators 63. Thus, the stator 63 may refer to the combination of non-rotating elements throughout the turbine engine 10.

[0048] In operation, the airflow exiting the fan section 18 is split so that a portion of the airflow is directed into the LP compressor 24, which then supplies the pressurized airflow 76 to the HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from the HP compressor 26 is mixed with the fuel in the combustor 30 and ignited, thereby generating combustion gases. The HP turbine 34 extracts some work from these gases, which drives the HP compressor 26. The combustion gases are exhausted into the LP turbine 36, which extracts additional work to drive the LP compressor 24, and the exhaust gas is ultimately exhausted from the turbine engine 10 via the exhaust section 38. The drive of the LP turbine 36 drives the LP spool 50 to rotate the fan 20 and the LP compressor 24.

[0049] A portion of the pressurized air flow 76 may be extracted from the compressor section 22 as bleed air 77. The bleed air 77 may be extracted from the pressurized air flow 76 and provided to engine components for cooling. The temperature of the pressurized air flow 76 entering the combustor 30 is significantly increased to above the bleed air temperature. The bleed air 77 may be used to reduce the temperature of core components downstream of the combustor 30.

[0050] The remaining portion of the pressurized airflow 76 bypasses the LP compressor 24 and the engine core 44 as a bypass airflow 78 and exits the turbine engine 10 through a stationary vane row at the fan exhaust side 84, and more specifically, exits the turbine engine 10 through an exit guide vane assembly 80 (including a plurality of airfoil guide vanes 82) at the fan exhaust side 84. More specifically, a circumferential row of radially extending airfoil guide vanes 82 are used adjacent the fan section 18 to exert some directional control on the airflow 78.

[0051] Some of the air supplied by the fan 20 may bypass the engine core 44 and be used to cool portions of the turbine engine 10, particularly the hot portions, and / or to cool or power other aspects of the aircraft. In the case of a turbine engine, the hot portions of the engine are typically downstream of the combustor 30, particularly the turbine section 32, with the HP turbine 34 being the hottest portion as it is located directly downstream of the combustion section 28. Other sources of cooling fluid may be, but are not limited to, fluid discharged from the LP compressor 24 or the HP compressor 26.

[0052] Figure 2 Is suitable for Figure 1 1 is a schematic perspective view of a composite airfoil 100 and a disk 102 for use within a turbine engine 10 of FIG. Composite airfoil 100 may define a body 104. Disk 102 is suitable for use as disks 61, 71 ( Figure 1 ) or any other disk, such as but not limited to turbine engine 10 ( Figure 1 ) of fan section 18 ( Figure 1 )、Compressor section 22( Figure 1 ) or turbine section 32 ( Figure 1 ) within the disk. The composite airfoil 100 may be rotating or non-rotating, such that the composite airfoil 100 may include static compressor blades 60, 62 ( Figure 1 ), the set of compressor blades 56, 58 ( Figure 1 ), static turbine blades 72, 74 ( Figure 1 ), the group of turbine blades 68, 70 ( Figure 1 ) or a plurality of fan blades 42 ( Figure 1 ). As a non-limiting example, the composite airfoil 100 may be a composite fan blade.

[0053] The composite airfoil 100 and its body 104 extend between a leading edge 114 and a trailing edge 116 to define a chord-wise direction, and between a root 118 and a tip 120 to define a span-wise direction. The composite airfoil 100 includes a pressure side 122 and a suction side 124.

[0054] The disk 102 may rotate or be stationary about an axis of rotation 106. The axis of rotation 106 may be aligned with the engine centerline 12 ( Figure 1 ) coincident, parallel, or offset. The disk 102 includes a plurality of slots 108 extending axially through a radially outer surface 112 of the disk 102. The plurality of slots 108 are circumferentially spaced about the disk 102 relative to the axis of rotation 106 and allow the composite airfoil 100 to be slidably secured to the disk 102.

[0055] The composite airfoil 100 is coupled to the disk 102 by inserting at least a portion of the composite airfoil 100 into a corresponding slot in the plurality of slots 108. The composite airfoil 100 is held in place by frictional contact with the slot 108, or may be coupled to the slot 108 via any suitable coupling method, such as, but not limited to, welding, bonding, fastening, etc. Although only a single composite airfoil 100 is shown, it should be understood that any number of composite airfoils 100 may be coupled to the disk 102. As a non-limiting example, there may be a number of composite airfoils 100 corresponding to the total number of slots in the plurality of slots 108.

[0056] For ease of reference, a set of relative reference directions and coordinate systems may be applied to the composite airfoil 100 and the disk 102. The axial direction (Ad) may extend from front to back and is shown as extending at least partially into the page. The axial direction (Ad) may be arranged parallel to the rotation axis 106, which may also be arranged parallel to the engine centerline 12 ( Figure 1 ). The radial direction (Rd) extends perpendicular to the axial direction (Ad), and the radial direction (Rd) may extend perpendicular to the engine centerline 12. The circumferential direction (Cd) may be defined as perpendicular to the radial direction (Rd), and the circumferential direction (Cd) may be defined as a ray extending from or along the curvature of a circumference around the axial direction (Ad), may be defined as a ray extending locally from the radial direction (Rd), and / or may be defined as a ray extending relative to the engine centerline 12 ( Figure 1 ) or the axis of rotation 106 along the turbine engine 10 ( Figure 1 )’s circumference.

[0057] Figure 3 A schematic diagram of an automated fiber placement assembly 150 is shown applying a fiber bundle 152 to a component 154 to at least partially form the component 154. In one non-limiting example, the component 154 may be Figure 2 The composite airfoil 100 of FIG. 1 is shown, however, non-turbine engine components are contemplated. As shown, the fiber tow tape 152 includes five individual bundles, however, any number of bundles forming the fiber tow tape 152 are contemplated. Roller 156 is used to apply the fiber tow tape 152 to a component 154 in a feed direction. Multiple layers of the fiber tow tape 152 may be applied in this manner to form a component.

[0058] Figure 3 1 and 16. The cutter head assembly 160 schematically shown in FIG. 1 is spaced from a back plate 162. The fiber bundle 152 is fed between the cutter head assembly 160 and the back plate 162, allowing the fiber bundle 152 to be cut to any length or position against the back plate 162. A vacuum device 164 may be positioned behind, at, or near the cutter head assembly 160 to remove fiber bundle trimmings generated when the cutter head assembly 60 cuts the fiber bundle 152.

[0059] The cutter head assembly 160 includes a cutter head 170 coupled to an actuator 172, which actuates the cutter head 170 to cut the fiber bundle 152 against the back plate 162. In one example, the actuator 172 may include a fixed body and a movable body, thereby allowing the movable body to be actuated relative to the fixed body. For example, the fixed body may be a mounting member, and the movable body may be moved by current, pressure or other force generation. In a non-limiting example, an additional mover including the actuator 172 may include a linear motor or a rotary motor. The shape of the cutter head 170 is defined as a cutting shape or cutting pattern formed in the cut fiber bundle 152 after the cutting is completed. The cutter head 170 may be removably attached to the actuator 172, thereby allowing the interchange of the cutter head 170. The actuator 172 may move the cutter head 170, so as to move in the rotational direction ROTd to change the orientation of the cutter head 170 relative to the fiber bundle 152. In this manner, the cutter head assembly 160 may be used to cut the fiber bundle 152 in various orientations, discussed in further detail herein, and including those orientations that include portions that deviate from orthogonal or are arranged non-orthogonally relative to the longitudinal extent of the fiber bundle 152 .

[0060] The cutter head assembly 160 or other elements (such as the vacuum device 164, the actuator 172, or the roller 156) can be communicatively and operably coupled to the controller 174. For example, the controller 174 can include a memory for programming software or operating software, and a processor for performing tasks or running software. The controller 174 can be used to control the operation of the automatic fiber placement assembly 150 (such as locally controlled by a user, or remotely controlled via a remote communication device), as well as electronically communicate with the cutter head assembly 160 or other elements (such as the vacuum device 164, the actuator 172, the roller 156, or a combination thereof).

[0061] refer to Figure 4 , provides more details Figure 3The cutter head assembly 160, wherein the cutter head 170 is arranged as a group of at least two cutter heads, is shown as a group of cutter heads 180 including five exemplary cutter heads 182 arranged along the fiber bundle 152, wherein the individual cutter heads 182 can be arranged to complement the individual bundles of the fiber bundle 152. In alternative examples, any number of cutter heads 182 can be envisioned, including one or more, such as at least two cutter heads 182 or a group of multiple cutter heads 182.

[0062] Each cutter head 182 may be coupled to a dedicated actuator 184 that collectively defines the actuator 172 and allows for independent movement, rotation, operation, or actuation of each cutter head 82, as well as independent, partial, or collective movement between the set of cutter heads 180. That is, each of the cutter heads 182 may be independently operated or moved relative to one another via their respective dedicated actuators 184.

[0063] In addition, each dedicated actuator 184 can move in the rotation direction ROTd, the actuation direction ACTd or the lateral direction LATd, and a combination thereof. The mounting member 186 couples the dedicated actuator 184 to the base 190. In a non-limiting example, the mounting member 186 can allow movement when each of the cutter heads 182 rotates in the rotation direction ROTd via the actuator 184. More specifically, the mounting member 186 can include a motor or a drive system, or other moving system, so as to allow the mounting member to move relative to the base 190 or along the base 190, and to allow the rotational movement of the dedicated actuator 184, and even its actuation. In another non-limiting example, the mounting member 186 can move in the lateral direction LATd along the base 190, such as by a drive system (not shown). In yet another non-limiting example, it is conceivable that the mounting member 186 can allow or drive the actuation of the dedicated actuator 184, which can be done individually, together, or by actuating less than all the cutter heads 182 in a non-limiting example. Thus, with each cutter head 182 being able to move individually, different or complex cutting shapes or cutting patterns are created for the end of the fiber bundle 152, such as a first cutting shape shown as a first sawtooth cutting pattern 188, or a second cutting shape shown as a second sawtooth cutting pattern 192, as shown in FIG. Figure 4 Such individual control of the cutter head 182 allows a plurality of different or complex cutting shapes to be formed or created without having to change one or more of the cutter heads 182 , the actuator 172 , or the entire cutter head assembly 160 .

[0064] If you can Figure 4As understood in the present invention, the set of cutter heads 180 can define a first cutting shape as a first sawtooth cutting pattern 188 and a second cutting shape as a second sawtooth cutting pattern 192, wherein the second cutting shape is different from the first cutting shape. More specifically, the first cutting shape is a mirrored version of the second cutting shape, thereby defining the difference between the first and second cutting shapes, and other suitable differences between the first cutting shape and the second cutting shape will be understood herein. In order to achieve each of the first cutting shape and the second cutting shape, the cutter head 182 is rotated to be rotationally offset relative to the adjacent cutter head 182, thereby defining the first and second sawtooth cutting patterns 188, 192. Although the cutter heads 182 shown have a gap or spacing at the tip, which is not reflected in the first and second sawtooth cutting patterns 188, 192, it should be understood that the gap or spacing is only for ease of understanding so that the reader can intuitively understand the different rotational orientations of each cutter head 182 relative to the next cutter head. Similarly, gaps are shown between the cut portions of the fiber bundle 152 at the first zigzag cutting pattern 188 and the second zigzag cutting pattern 192, which should be understood to be for the purpose of intuitively understanding the cutting of the fiber bundle 152, and the actual cutting operation may or may not include such gaps. It should be understood that the specific position or geometry of each of the cutter heads 182 can be arranged to have no gaps or spacing between adjacent cutter heads 182, thereby producing a consistent cutting pattern without gaps or spacing in the cut fiber bundle 152. In a non-limiting example, such spacing between adjacent cutter heads 182 can be changed (or eliminated) by movement of a dedicated actuator 184 or mounting member 186 in the transverse direction LATd.

[0065] In operation, the cutter head assembly 160 and the group of cutter heads 180 can be arranged to form a first cutting shape, represented in a first sawtooth cutting pattern 188. The cutter head assembly 160 can be actuated, such as by the actuator 172, to cut the fiber bundle 152 in a first cutting shape (such as the first sawtooth cutting pattern 188). The group of cutter heads 180 or the individual cutter heads 182 therein can be moved relative to their positions defining the first cutting shape, thereby defining a second cutting shape different from the first cutting shape. In a non-limiting example, such movement can include rotation in a rotational direction ROTd, or movement in an actuation direction ACTd or a transverse direction LATd, and additional movement can include pivoting, sliding, translating, or any other change in a position different from the position represented in the first cutting shape. The movement of the group of cutter heads 180 or the individual cutter heads 182 defines a second cutting shape. The cutter head assembly 160 can be actuated again to cut the fiber bundle 152 in a second shape. In this manner, the cutter head assembly 160 is capable of making cuts in the fiber bundle 152 in a variety of different cut shapes without having to change or replace the cutter head assembly 60. Although the first and second cut shapes are shown as sawtooth cut patterns 188, 192, it should be understood that any suitable shape or pattern may be used to form the first and second cut shapes, such as Figure 5 or other non-serrated shapes or partially serrated shapes.

[0066] It is contemplated that each of the individual cutter heads 182, the dedicated actuators 184, the mounts 186, the base 190, or a combination thereof may be operably coupled to the controller 174 to allow for individual control of the movement of the cutter head 182. In this manner, changes in the cutter head 182, which are collectively controlled by the controller 174, may be used to define a variety of cutting shapes or cutting patterns without changing the cutter head assembly 160. Additionally, the controller 174 may allow for automatic changes between cutting shapes, wherein such automation may be programmed into the controller 174, or may be made specific to a particular component or portion thereof being formed. More specifically, the controller 174 may automatically change between a first cutting shape and a second cutting shape, and between any additional cutting shapes.

[0067] refer to Figure 5 , showing different exemplary fiber bundles 152, each labeled as fiber bundles 152a-152f, depicting the fiber bundles that can be Figure 4The cutter head assembly 160 can be used to create different cutting shapes or cutting patterns. Each fiber bundle band 152a-152f has a first end 200 and an opposite second end 202, and has a longitudinal axis 204 extending between the first end 200 and the second end 202, and the longitudinal axis 204 can be arranged to be parallel to the individual bundles of the fiber bundle band 152.

[0068] The first fiber bundle band 152a may include an angled end 206 defining an angled cut shape. The angled end 206 may be arranged at an angle 208 relative to an axis 210, which is arranged perpendicular to the longitudinal axis 204 of the first fiber bundle band 152a. As shown, the angled end 206 is arranged at an angle 208 that deviates from perpendicular to the longitudinal axis 204. In a non-limiting example, the angle 208 may extend from 1 degree to 89 degrees, or from 91 degrees to 179 degrees (1°-89° or 91°-179°), where 90 degrees (90°) is parallel to the longitudinal axis 204. In an alternative example, the angled end 206 may be arranged perpendicular to the longitudinal axis 204, or non-orthogonal to the longitudinal axis 204.

[0069] The second fiber bundle 152b can include a curved end 212 that defines a curved cut shape. The curved end 212 can include a uniform curvature, such that the curvature defining the curved end 212 includes a constant radius of curvature, or shares a common center point. In one example, the curved end 212 can be parabolic, defining a parabolic end or a parabolic cut shape, having a parabolic curvature that at least partially defines a parabola. In another non-limiting example, the curved end 212 can include an increasing or decreasing radius of curvature. The third fiber bundle 152c shows an alternative curved end 214 that defines another curved cut shape. The alternative curved end 214 can include an oval curvature or an elliptical curvature, which can at least partially define an oval or elliptical shape, which can define an oval end, an oval cut shape, an elliptical end, or an oval cut shape. In non-limiting embodiments, it is contemplated that the bundle may be cut with a cut shape including a curved end that is parabolic, hyperbolic, elliptical, circular, oval, or follows a square, exponential, or logarithmic curvature, or other curvature, or a combination thereof. As can be appreciated, the curvature defined by the curved end 214 or the curved cut shape may include a local radius of curvature aligned with the edge 216 of the third fiber bundle band 152c formed as a rounded edge 219.

[0070] The fourth fiber bundle 152d can include a triangular end 220 or a triangular cut shape having a tip with a point 224 and including two linear portions 222 connected at the point 224. In additional non-limiting examples, the triangular end 220 or the triangular cut shape can include a symmetrical or asymmetrical arrangement, wherein the symmetrical arrangement can be defined along the longitudinal axis 204 extending through the point 224. More specifically, the angle or orientation of each linear portion 222 arrangement can be complementary to or independent of another linear portion 222. In another non-limiting example, it is contemplated that the point 224 is curved or rounded. The fifth fiber bundle 152e can include a trapezoidal end 226 defining a trapezoidal cut shape, defining three sides of the trapezoidal shape. The trapezoidal end 226 includes three linear portions 228 defining three sides of the trapezoid that intersect at a point 230. In alternative examples, any number of linear portions 228 or linear portions 222 arranged at any angle, perpendicular or non-angled relative to the longitudinal axis 204, the linear portions 228 or other linear portions 222 are contemplated for the fifth fiber bundle band 152e or individual bundles thereof. In non-limiting examples, the points 224, 230 defined at the locations where the linear portions 222 or linear portions 228 meet may be rounded or pointed.

[0071] Although the fourth and fifth fiber tow bands 152d and 152e are shown as triangular and trapezoidal cut shapes, any geometric shape is contemplated when defining the cut shape. Non-limiting examples of additional geometric shapes include square, triangle, rectangle, trapezoid, circle, hexagon, or combinations thereof.

[0072] The sixth fiber bundle 152f may include a combined end 232 or a combined cut shape, which may include a combination of ends or cut shapes, such as a combination of linear and curved cut shapes, or a cut shape that does not match a linear or curved profile. In one non-limiting example, the combined end 232 or the combined cut shape may be formed according to the part 154 ( Figure 3 ) shapes, where such geometries are outside of standard curved, linear or geometric cut shapes.

[0073] It should be understood that Figure 4 The set of cutter heads 180 can be used to create a number of different cutting shapes or cutting patterns, such as Figure 5 . In this way, precise cut shapes can be achieved, which can reduce waste, as well as reduce material costs, manufacturing costs and time. The ability to specifically or deterministically cut the fiber bundle 152 during application can allow for the formation of complex shapes or patterns that would otherwise be impossible without detailed finishing of the part.

[0074] Figure 6 Another exemplary automatic fiber placement assembly 300 is shown, which includes a first cutter head assembly 302 and a second cutter head assembly 304 spaced apart from the first cutter head assembly 302. A back plate 306 is positioned behind the first and second cutter head assemblies 302, 304, while it is contemplated that a dedicated back plate is provided for each of the first and second cutter head assemblies 302, 304. A fiber band 316 is disposed between the back plate 306 and the first and second cutter head assemblies 302, 304. A first vacuum device 308 is disposed at the first cutter head assembly 302, and a second vacuum device 310 is disposed at the second cutter head assembly 304, while it is contemplated that a single or single vacuum system is used for the automatic fiber placement assembly 300. The first cutter head assembly 302 also includes a cutter head 320 coupled to an actuator 322, which actuates the cutter head 320 to cut the fiber band 316 against the back plate 306. The second cutter head assembly 304 also includes a cutter head 324 coupled to an actuator 326 that actuates the cutter head 324 to cut the fiber bundle 316 against the backing plate 306. Alternatively, each of the first cutter head assembly 302 and the second cutter head assembly 304 may include a set of cutter heads (such as Figure 4 The set of cutter heads 180) can be configured to allow for a variety of different cutting shapes or cutting patterns.

[0075] The cutter head assemblies 302, 304 may be automated or programmable cutting tools operably coupled to a controller 318 that may be programmed to cut complex shapes or patterns into the fiber tow band 316. The automated fiber placement assembly 300 utilizing the first and second cutter head assemblies 302, 304 allows the fiber tow band 316 to be cut at the first end 312 and the second end 314, respectively, without having to change the cutter at the second end 314.

[0076] In this manner, it should be appreciated that complex cut shapes or cut patterns can be achieved at either of the first and second ends 312, 314 of the fiber bundle 316 through the dual cutter system of the first and second cutter head assemblies 302, 304, thereby reducing or eliminating the need to change the cutter heads 320, 324 to achieve different cut shapes or cut patterns at either of the first and second ends 312, 314. Figure 4The set of cutter heads 180) can allow for a plurality of different cutting shapes or cutting patterns, but there may be patterns that cannot be achieved with only a single cutter head assembly, despite the ability to change between a first cutting shape and a different second cutting shape. Using the first and second cutter head assemblies 302, 304 can achieve a wider array of cutting shapes or cutting patterns than using only a single cutter head, and reduce or eliminate the need to change the cutter head during operation.

[0077] refer to Figure 7 , another exemplary automated fiber placement assembly 400 includes a cutter head assembly 402 for cutting a fiber tow band 404 against a backing plate 406. Similar to the discussion above, the automated fiber placement assembly 400 can include rollers 408 for rolling the fiber tow band 404 along a component 410. A vacuum device 412 can be positioned near, at, or adjacent to the cutter head assembly 402 to remove shavings from the fiber tow band 404.

[0078] The cutter head assembly 402 can be an automatic or programmable cutting tool operably coupled to the controller 414, which can be programmed to cut the fiber bundle 404 into different cut shapes, including complex shapes or patterns at either or both ends, at any position along the fiber bundle 404, or a combination thereof. In one non-limiting example, the cutter head assembly 402 can be a laser cutter, which can be programmed to cut a specific cut shape or cut pattern into the fiber bundle 404 or its individual bundles. In another non-limiting example, the cutter head assembly 402 can be a knife-type cutter (such as a vibrating knife) that translates on the fiber bundle 404 in directions parallel to and perpendicular to the longitudinal axis 420 defined along the fiber bundle 404 to create any contour, cut pattern, or cut shape for the end of the fiber bundle 404 or even along any portion of the fiber bundle 404.

[0079] The back plate 406 may optionally be a cooled back plate, wherein the back plate 406 is actively cooled by a cooling system 416. A non-limiting example of the cooling system 416 may include a heat exchanger 418 coupled to the back plate 406. Heat may be generated using a cutter head assembly 402, such as a laser cutter. The fiber bundle 404 may be treated, such as with a resin, which may be activated by adding heat. Therefore, to prevent premature activation, the fiber bundle 404 may be actively cooled by the back plate 406 to ensure proper or timely activation of the resin or material within the fiber bundle 404.

[0080] Figure 8 A diagram depicting a component such as a turbine engine (eg, Figure 1 The turbine engine 10 and Figure 3 and Figure 7 410). At 502, the method 500 may include attaching a cutter head assembly (such as the cutter head assembly 160, 302, 304, 402) to an automated fiber placement assembly (such as the automated fiber placement assembly 150, 300, 400). The attachment of a particular cutter head assembly 160, 302, 304, 402 may be determined based on the particular component 154, 410 being prepared, and the cutter head assembly 160, 302, 304, 402 may be pre-arranged or pre-oriented with a particular first cutting shape or cutting pattern of the fiber bundle 152, 316, 404 to be cut.

[0081] At 504, the method 500 may include orienting the cutter head assembly 160, 302, 304, 402. For example, orienting the cutter head assembly 160, 302, 304, 402 may be accomplished by rotating a cutter head, such as a cutter head 170, 182, 320, 324, using the mount 186. For example, where the cutter head assembly 160, 302, 304, 402 is not pre-arranged or pre-oriented in a first cutting configuration, the method 500 may include moving the cutter head assembly 160, 302, 304, 402 or its cutter head 170, 182, 320, 324 to the first cutting configuration. Orienting the cutter head assembly 160, 302, 304, 402 may include rotating the entire cutter head assembly 160, 302, 304, 402, or rotating one or more individual cutter heads 170, 182, 320, 324 (such as cutter heads 170, 182, 320, 324) of the cutter head assembly 160, 302, 304, 402 to define a first cutting shape or cutting pattern. Additionally, the orientation may include moving, translating, shifting, rotating, pivoting, retracting, extending, or a combination thereof, such as in one or more of a rotational direction ROTd, an actuation direction ACTd, or a lateral direction LATd, the cutter head 170, 182, 320, 324 or the actuator 172 to orient the cutter head assembly 160, 302, 304, 402 to the first cutting shape or cutting pattern.

[0082] At 506, the method 500 may include applying the fiber bundle band 152, 316, 404 to the component 154, 410, or applying the fiber bundle band 152, 316, 404 to form the component 154, 410, such as the composite airfoil 100, its body 104. In a non-limiting example, the application of the fiber bundle band 152, 316, 404 can be applied in a feed direction by a roller (such as the roller 156, 408 described herein). The feed direction can be aligned with the longitudinal extent of the fiber bundle band 152, 316, 404, while tilted or offset application can be envisioned. Control of the application speed and starting or stopping the feed can be achieved by the roller, for example, the roller can be controlled by a controller (such as the controller 174, 318, 414). In another non-limiting example, the fiber bundle band 152 can be applied to the substrate. In non-limiting examples, the substrate may be a previous layer of the fiber bundle 152, 316, 404, the component 154, 410, or a mandrel. In this manner, the application of the fiber bundle 152, 316, 404 may be defined by any application during the formation of the component 154, 410, such as application to a previous fiber bundle layer or directly to a mandrel or other feature used to form the component 154, 410.

[0083] At 508, the method 500 may include cutting at least one fiber bundle of the fiber bundle band 152, 316, 404 with a first cutting shape with a cutter head assembly 160, 302, 304, 402. In one non-limiting example, cutting may include actuating the cutter head assembly 160, 302, 304, 402 with an actuator so that the cutter head 170, 182, 320, 324 cuts at least one fiber bundle of the fiber bundle band 152, 316, 404. Such cutting may be achieved by actuating the cutter head assembly 160, 302, 304, 402 until the cutter head 170, 182, 320, 324 contacts a backing plate (such as a backing plate 162, 306, 406) to ensure that the cut has been achieved. In another non-limiting example, the cutting may be achieved with a laser cutter that uses a laser to cut the fiber bundle band 152, 316, 404 with a first cutting shape or cutting pattern. In yet another non-limiting example, cutting may be accomplished with a vibrating cutter that translates across the fiber tow band 152, 316, 404 in a predetermined path or pattern to achieve a first cut shape or cut pattern.

[0084] At 510, the method 500 may include redirecting the cutter head assembly 160, 302, 304, 402, which may include moving the cutter head assembly 160, 302, 304, 402 or its cutter head 170, 182, 320, 324 from a first cutting shape to a second cutting shape different from the first cutting shape. In a non-limiting example, the redirection may include moving, translating, transferring, rotating, pivoting, retracting, extending, or a combination thereof, such as in one or more directions of a rotational direction ROTd, an actuation direction ACTd, or a transverse direction LATd, to define a second cutting shape or cutting pattern different from the first cutting shape or cutting pattern. When the cutter is a laser cutter or a vibrating cutter, redirecting the cutter head assembly 160, 302, 304, 402 may include programming a new or different cutting shape or cutting pattern, such as with a controller 174, 318, 414 operably or communicatively coupled to the cutter head assembly 160, 302, 304, 402.

[0085] At 512, the method 500 may include cutting a second end, such as the second end 202, 314 of the fiber bundle 152, 316, 404 or an individual bundle thereof, in a second cutting shape. Additionally, it is further contemplated that the cutter head assembly 160, 302, 304, 402 may cut a middle portion of the fiber bundle 152, 316, 404, including any portion or location between the first end 200, 312 and the second end 202, 314, in the second cutting shape to create a different cutting shape or cutting pattern along the length of the fiber bundle 152, 316, 404. In such an example, it is contemplated that the cutter head assembly 160, 302, 304, 402 may be redirected to a third cutting shape that is different from the first cutting shape and the second cutting shape to cut the middle portion of the fiber bundle 152, 316, 404, and then redirected again to the second cutting shape to cut the second end 202, 314. In this case, the cutter head assembly 160, 302, 304, 402 can be oriented to a first cutting shape to cut the first end 200, 312, moved to a third cutting shape to cut the middle portion of the fiber bundle 152, 316, 404, and then moved to a second cutting shape to cut the second end 202, 314 without having to move to the second cutting shape before moving to the third cutting shape.

[0086] At 514, the method 500 may include curing or finishing the component 154, 410. In one non-limiting example, curing the component 154, 410 may include cooling the component 154, 410, such as with a heat exchanger 418. In another non-limiting example, the component 154, 410 may be finished by applying an external material or coating, such as an external barrier or paint coating, and additional finishing processes or actions are also within the scope of the present disclosure.

[0087] Aspects described herein provide a process or method 500 for forming a component 154, 410, such as a composite airfoil 100 or a portion thereof. The cutter head assembly 160, 302, 304, 402 is used to create complex cutting shapes and cutting patterns, which reduces waste and finishing, thereby reducing time and cost. In addition, it should be understood that the method 500 should not be used as Figure 8 The illustration is limited, and aspects of the illustrated method 500 may be rearranged, repeated, or removed to define a different method among a variety of methods, which is also within the scope of the present disclosure.

[0088] The benefits associated with using a cutter head assembly for an automated fiber placement assembly or method as described herein provide improved shaping and precision for the fibers applied during the formation of the component. This improved cutting provides reduced waste and finishing, thereby reducing cost and manufacturing time. Utilizing a cutter head assembly with multiple movable cutter heads allows complex shapes to be created for the applied fibers, providing improved shaping and precision, thereby further reducing cost and time. In addition, the automated fiber placement assembly allows different cutting shapes to be utilized, which reduces or eliminates changes to the cutter head during manufacturing, while a dedicated vacuum device reduces the need for separate cleaning of waste trimmings.

[0089] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any device or system and performing any combined method. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0090] Further aspects are provided by the subject matter of the following clauses:

[0091] An automated fiber placement assembly for forming a component utilizing a fiber band defining a longitudinal axis includes a first cutter head assembly defining a first cutting shape and being movable to define a second cutting shape different from the first cutting shape.

[0092] The automated fiber placement assembly of any preceding clause, wherein at least a portion of one of the first cutting shape or the second cutting shape is arranged non-orthogonal to the longitudinal axis.

[0093] An automated fiber placement assembly according to any preceding clause, wherein the first cutter head assembly comprises a set of at least two cutter heads, wherein each cutter head in the set of at least two cutter heads is capable of moving independently of the other cutter heads in the set of at least two cutter heads.

[0094] An automated fiber placement assembly according to any preceding clause, wherein each of the at least two cutter heads is movable to cut at least a portion of the fiber band that is non-orthogonal to the longitudinal axis.

[0095] The automated fiber placement assembly of any preceding clause, wherein the first cutter head assembly comprises at least two cutter heads, and wherein the at least two cutter heads are movable to collectively define the first cutting shape and the second cutting shape.

[0096] The automated fiber placement assembly of any preceding clause, wherein the first cutting shape defined by the at least two cutter heads is one of an angled cutting shape, a curved cutting shape, a triangular cutting shape, a trapezoidal cutting shape, or a combined cutting shape.

[0097] The automated fiber placement assembly of any preceding clause, further comprising a second cutter head assembly, wherein the second cutter head assembly is movable to cut a third cut shape different from at least one of the first cut shape and the second cut shape.

[0098] The automated fiber placement assembly of any preceding clause, further comprising a vacuum device positioned adjacent the first cutter head assembly.

[0099] The automated fiber placement assembly of any preceding clause, wherein the first cutter head assembly comprises a cutter head removably attached to the first cutter head assembly.

[0100] The automated fiber placement assembly of any preceding clause, further comprising a backing plate spaced apart from the first cutter head assembly.

[0101] The automated fiber placement assembly of any preceding clause, further comprising a cooling system operably coupled to the backing plate.

[0102] An automated fiber placement assembly as described in any preceding clause, wherein the component is a gas turbine engine component.

[0103] The automated fiber placement assembly of any preceding clause, wherein at least one of the first cutting shape or the second cutting shape defines a curved shape having a different radius of curvature.

[0104] The automated fiber placement assembly of any preceding clause, wherein at least one of the first cutting shape or the second cutting shape defines a parabolic curvature.

[0105] The automated fiber placement assembly of any preceding clause, wherein at least one of the first cutting shape or the second cutting shape defines an oval curvature.

[0106] The automated fiber placement assembly of any preceding clause, wherein at least one of the first cutting shape or the second cutting shape defines an elliptical curvature.

[0107] The automated fiber placement assembly of any preceding clause, wherein at least one of the first cutting shape or the second cutting shape defines a combined curvature.

[0108] An automated fiber placement assembly for forming a component utilizing a fiber band defining a longitudinal axis, the automated fiber placement assembly comprising: a first cutter head assembly including a cutter head defining a first cutting shape; wherein the cutter head is movable from the first cutting shape to a second cutting shape.

[0109] An automated fiber placement assembly according to any preceding clause, wherein the first cutter head assembly comprises a set of at least two cutter heads, wherein each cutter head in the set of at least two cutter heads is capable of moving independently of the other cutter heads in the set of at least two cutter heads.

[0110] The automated fiber placement assembly of any preceding clause, further comprising a set of at least two vacuum devices, wherein one vacuum device of the set of at least two vacuum devices is positioned at each cutter head of the set of at least two cutter heads.

[0111] The automated fiber placement assembly of any preceding clause, further comprising a set of at least two actuators, wherein one actuator of the set of at least two actuators is positioned at each cutter head of the set of at least two cutter heads.

[0112] An automated fiber placement assembly as claimed in any preceding clause, wherein the first cutter head assembly is a laser cutter movable in directions parallel and perpendicular to the longitudinal axis.

[0113] An automated fiber placement assembly as claimed in any preceding clause, wherein the first cutter head assembly comprises an oscillating knife which translates over the fiber tow band in directions parallel and perpendicular to the longitudinal axis.

[0114] An automated fiber placement assembly as described in any preceding clause, wherein the component is a gas turbine engine component.

[0115] A method of forming a component, the method comprising: applying a fiber tow band to a substrate in a feed direction; cutting the fiber tow band with a cutter head assembly to define a first cut shape; and moving the cutter head assembly to define a second cut shape different from the first cut shape.

[0116] A method according to any preceding clause, wherein at least a portion of the first cutting shape or the second cutting shape is non-orthogonal to the feed direction.

[0117] A method according to any preceding clause, wherein the cutter head assembly includes a group of multiple cutter heads; and wherein moving the cutter head assembly further includes moving at least one cutter head of the group of multiple cutter heads to change the first cutting shape to the second cutting shape.

[0118] The method of any preceding clause, further comprising cutting the fiber band with the cutter head assembly defining the second cutting shape.

[0119] The method of any preceding clause, wherein moving the cutter head assembly further comprises reorienting the cutter head assembly to define the second cutting shape.

Claims

1. An automated fiber placement assembly for forming a component using a fiber band, the fiber band defining a longitudinal axis, characterized in that The automated fiber placement assembly comprises: A first cutter head assembly defines a first cutting shape and is movable to define a second cutting shape different from the first cutting shape.

2. The automatic fiber placement assembly according to claim 1, characterized in that in, At least a portion of one of the first cutting shape or the second cutting shape is arranged non-orthogonal to the longitudinal axis.

3. The automatic fiber placement assembly according to claim 1, characterized in that in, The first cutter head assembly includes a set of at least two cutter heads, wherein each cutter head of the set of at least two cutter heads is movable independently of the other cutter heads of the set of at least two cutter heads.

4. The automatic fiber placement assembly according to claim 2, characterized in that: in, Each of the at least two cutter heads is movable to cut at least a portion of the fiber band that is non-orthogonal to the longitudinal axis.

5. The automatic fiber placement assembly according to claim 1, characterized in that: in, The first cutter head assembly includes at least two cutter heads, and wherein the at least two cutter heads are movable to collectively define the first cutting shape and the second cutting shape.

6. The automatic fiber placement assembly according to claim 5, characterized in that in, The first cutting shape defined by the at least two cutter heads is one of an inclined cutting shape, a curved cutting shape, a triangular cutting shape, a trapezoidal cutting shape, or a combined cutting shape.

7. The automated fiber placement assembly of claim 1, wherein: Further included is a second cutter head assembly, wherein the second cutter head assembly is movable to cut a third cutting shape different from at least one of the first cutting shape and the second cutting shape.

8. The automated fiber placement assembly of claim 1, wherein: Further included is a vacuum device positioned adjacent to the first cutter head assembly.

9. The automated fiber placement assembly of claim 1, wherein: in, The first cutter head assembly includes a cutter head removably attached to the first cutter head assembly.

10. The automated fiber placement assembly of claim 1, wherein: Further included is a back plate spaced apart from the first cutter head assembly.

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