Aircraft Aerofoil Trailing Edge Ramp Lay-Up Without Machining
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Solution Overview
Problem
The machining operation to achieve the correct profile at the trailing edge interface of aircraft aerofoils is costly and time-consuming, leading to wastage.
Innovation Solution
A method of manufacturing aircraft aerofoils involving a lay-up step to form preforms with decreasing thickness ramps, followed by curing to create contact surfaces, and assembling the trailing edge interface by engaging these surfaces, optionally with fasteners, to join the covers without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining operation is used to achieve the correct profile at the trailing edge interface, then manufacturing precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The fibre plies are laid up with a ramp of decreasing thickness during the initial lay-up step, so that the correct trailing edge profile is prepared in advance. This preliminary shaping eliminates the need for subsequent machining operations to achieve the correct profile, resolving the contradiction between precision and productivity.
Solution Approach 2:
The ramp of decreasing thickness is formed during the lay-up step before curing, so that the contact surface geometry is predetermined. This advance preparation allows the trailing edge interface to be ready for assembly without requiring time-consuming post-curing machining.
2Manufacturing precision
If machining operation is used to achieve the correct profile at the trailing edge interface, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The correct trailing edge profile is built into the preform during the lay-up step through the ramp of decreasing thickness. This preliminary formation of the accurate geometry eliminates costly machining operations, achieving high precision without increased manufacturing cost.
Solution Approach 2:
The invention extracts the machining operation from the manufacturing process entirely. By forming the correct profile directly during lay-up through the ramp structure, the need for separate machining steps is removed, eliminating associated costs while maintaining precision.
3Manufacturing precision
If machining operation is used to achieve the correct profile at the trailing edge interface, then manufacturing precision is improved, but material wastage increases
Solution Approach 1:
The ramp of decreasing thickness is formed during the lay-up step, so that the correct trailing edge profile is established before curing. This preliminary shaping uses the full material efficiently without requiring subsequent removal of material through machining, eliminating waste.
Solution Approach 2:
The invention changes the thickness parameter of the fibre plies gradually through the ramp structure during lay-up. This continuous parameter change from full thickness to zero at the trailing edge allows precise profile formation without material removal, preventing wastage while achieving the required precision.
Data Source
AI summary
A method of manufacturing an aircraft aerofoil such as a winglet. The aircraft aerofoil includes: a first cover, a second cover, an aerofoil leading edge, and an aerofoil trailing edge where the first and second cover are joined at a trailing edge interface. The first cover is formed by: a lay-up step in which a plurality of fibre plies are laid up to obtain a preform, wherein the preform has a thickness and a preform trailing edge, and the preform is laid up during the lay-up step with a ramp of decreasing thickness where the thickness of the preform decreases towards the preform trailing edge; and a curing step in which the preform is cured to form the first cover, wherein the ramp of decreasing thickness cures during the curing step to form a contact surface of the first cover.