Tooling System for Beveled Stiffened Panel Reinforcement Ends
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Solution Overview
Problem
The existing methods for manufacturing stiffened panels with beveled reinforcement ends are inefficient due to the need for post-consolidation machining and coating, which are time-consuming and require high attention to detail.
Innovation Solution
A tooling system that includes molds, inserts, and a sealing system with elastic coatings to form stiffened panels with beveled reinforcement ends before consolidation, eliminating the need for post-processing machining and ensuring precise positioning and sealing during polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If beveled end edges are created by post-consolidation machining, then the reinforcements have the required shape, but the manufacturing time increases and requires high attention to detail
Solution Approach 1:
The beveled end edges are formed during the consolidation process itself through the action of inclined inserts positioned in the mold, rather than being created by post-consolidation machining. This preliminary formation of the beveled shape eliminates subsequent machining operations and reduces manufacturing time while maintaining precision.
Solution Approach 2:
The beveling operation is extracted from the post-consolidation machining sequence and integrated into the consolidation process through dedicated inserts. This separates the bevel formation function from the final machining function, allowing beveled ends to be created during consolidation without requiring additional machining time.
2Manufacturing precision
If beveled end edges are created by post-consolidation machining, then the reinforcements have the required shape, but the process requires high attention to detail
Solution Approach 1:
The inserts with inclined contact surfaces automatically form the beveled end edges during consolidation through their geometric design. The process is self-guiding as the inserts inherently define the bevel angle and shape, eliminating the need for complex post-consolidation machining operations and reducing operational complexity.
Solution Approach 2:
The approach changes the operational parameters by forming beveled ends during consolidation rather than through post-consolidation machining. This parameter change transforms a complex machining operation into a simpler mold-based process, reducing attention to detail requirements while maintaining precision.
3Device complexity
If standard molds are used without inserts for beveled ends, then the tooling is simpler, but post-processing machining is required
Solution Approach 1:
The inserts are integrated into the molds to preliminarily form the beveled end edges during consolidation. This preliminary action eliminates the need for post-processing machining, significantly improving manufacturing efficiency despite the increased tooling complexity from adding inserts to the mold structure.
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
This approach reduces material waste and maintains high mechanical characteristics of the stiffened panels while simplifying the manufacturing process by integrating beveled end edges into the tooling system, eliminating the need for post-processing steps.
Implementation Method 1
The sealing system comprises an elastic coating, with a low coefficient of expansion, covering each contact surface, which extends on either side of the insert so as to be compressed between the first molds positioned on either side of the insert
Implementation Method 2
The fiber preforms 10 and the fiber plies 26 are consolidated simultaneously or co-cured, with the addition of resin if the fibers of the preforms 10 and plies 26 are dry
Data Source
Figure 1~5
Figure 6~9
Figure 10~12
AI summary
The invention relates to a tool for consolidating or polymerizing a stiffened panel comprising a panel and reinforcements attached to an inner face of the panel and parallel to each other, at least one of the reinforcements having at least one beveled end edge. This tool comprises a first mold (68) for each fiber preform, an insert (70) for each beveled end edge of the reinforcements against which, during operation, beveled end edges of the wings of two fiber preforms pressed together to form the reinforcement are pressed, as well as at least one holding and positioning element connecting the inserts (70) to each other.