Adjustable Die Forming for Composite Structural Members
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Solution Overview
Problem
Existing methods for forming composite structural members with complex contours, such as those with variations in thickness, curves, and angles, face challenges like wrinkling and require multiple mandrels, making them time-consuming and inefficient.
Innovation Solution
A method and apparatus using adjustable dies with motion control devices to form composite structural members by inserting a second die into a recess of a first die, allowing for transverse adjustment and tension stress on the charge, enabling the formation of complex shapes without mandrels and reducing wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If vacuum bag drape forming is used to form thick laminates with complex shapes, then the forming process can be automated, but wrinkling occurs in the plies
Solution Approach 1:
The apparatus employs movable and adjustable forming members that can dynamically adapt to complex geometries. The forming members are positioned by actuators and can be adjusted during the forming process to maintain optimal contact with the charge, preventing wrinkling while accommodating thick laminates and complex shapes.
Solution Approach 2:
The forming apparatus uses multiple separate forming members rather than a single vacuum bag. These forming members can be independently positioned and adjusted, allowing precise control over the forming process for each section of the charge, thereby preventing wrinkling in complex geometries.
2Manufacturing precision
If manual layup process is used to form contoured composite members, then complex contours can be achieved, but the process is time-consuming
Solution Approach 1:
The apparatus pre-positions multiple forming members according to the desired complex contour geometry before the forming process begins. This preliminary setup allows the system to automatically achieve precise contours without time-consuming manual layup operations during production.
Solution Approach 2:
The invention replaces the manual mechanical layup process with an automated forming system using actuators and programmable forming members. This substitution maintains the ability to create complex contours while dramatically increasing production speed and consistency.
3Adaptability or versatility
If multiple mandrels are used to form different configurations of composite members, then various shapes can be produced, but device complexity increases
Solution Approach 1:
The forming apparatus uses a set of standardized, adjustable forming members that can be repositioned and reconfigured to produce multiple different composite member configurations. This universal system replaces the need for multiple dedicated mandrels, reducing device complexity while maintaining versatility.
Solution Approach 2:
The forming members are designed to be movable and adjustable rather than fixed mandrels. This dynamic capability allows the same forming members to adapt to different configurations by changing their positions and orientations, eliminating the need for multiple static mandrels.
4Ease of manufacture
If charge is formed against a mandrel using vacuum bag, then the forming process is simplified, but wrinkling occurs in complex shapes
Solution Approach 1:
Instead of using a single vacuum bag, the invention segments the forming process into multiple forming members that can independently conform to different sections of the charge. This segmentation maintains process simplicity while preventing wrinkling through localized control.
Solution Approach 2:
The forming members are designed with adjustable positioning capabilities, allowing them to dynamically adapt to complex charge geometries. This dynamic adjustment maintains the simplicity of the forming process while achieving high surface quality by preventing wrinkling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient formation of composite structural members with complex geometries, reducing the need for multiple mandrels and minimizing wrinkling, thereby improving production efficiency and accuracy.
Implementation Method 1
The first die can also be adapted to restrain transverse motion of the charge so that the opposite surfaces of the charge are stressed in tension during forming
Implementation Method 2
the second die can be inserted into the recess of the first die, thereby adjusting the portions of the first die transversely outward and forming the charge between the first and second dies to the configuration of the structural member
Data Source
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AI summary
A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.