Composite Radius Filler Assembly With Angled Stiffness Transition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional composite radius fillers lack the ability to vary mechanical properties along their length, leading to potential distortion and mismatch with the composite structure during formation and curing, necessitating a need for composite radius fillers with variable mechanical properties.
Innovation Solution
The development of composite radius fillers with a body comprising a main-portion and an end-portion, where the main-portion and end-portion have different stiffnesses, and an interface between them at an angle relative to the longitudinal axis, allowing for variation in mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional composite radius fillers with uniform mechanical properties are used, then manufacturing is simpler, but distortion occurs during formation and curing due to mismatch with composite structure
Solution Approach 1:
The composite radius filler is divided into multiple segments along its longitudinal axis, with each segment having different mechanical properties (stiffness, strength) tailored to match specific regions of the composite structure. This segmentation allows the filler to provide appropriate mechanical support at different locations without causing distortion during formation and curing.
Solution Approach 2:
Different portions of the composite radius filler are assigned different local qualities, specifically varying stiffness and strength characteristics. The filler transitions from higher stiffness in regions requiring rigid support to lower stiffness in regions requiring flexibility, matching the local mechanical requirements of the composite structure being formed.
2Reliability
If composite radius filler has different stiffness in main-portion and end-portion, then distortion is reduced during curing, but manufacturing complexity increases
Solution Approach 1:
The composite radius filler is pre-constructioned with varying mechanical properties in different portions before being placed in the composite structure. The main-portion and end-portion are constructed with different stiffness characteristics in advance, allowing them to immediately provide the appropriate mechanical support during curing without requiring adjustment during the manufacturing process.
Solution Approach 2:
The filler utilizes composite material construction with varying fiber orientations, material compositions, or layer configurations in different portions. This allows the main-portion and end-portion to achieve different stiffness levels through material selection and arrangement, enabling tailored mechanical properties while maintaining manufacturability through established composite fabrication techniques.
Data Source
AI summary
A method comprises pressing a tool into a main-portion of a composite radius filler. Another method comprises changing a shape of at least a first main-portion surface of a main-portion of a composite radius filler by pressing a first tool surface of a tool into the first main-portion surface. A system comprises a tool and a composite radius filler comprising a body having a longitudinal axis. The body comprises a main-portion and an end-portion. The main-portion extends along the longitudinal axis and has a first stiffness. The body further comprises an end-portion that extends along the longitudinal axis, that is adjacent to the main-portion, and that has a second stiffness that differs from the first stiffness. At least a first portion of an interface between the main-portion and the end-portion is at an angle relative to the longitudinal axis.