Cam-Closing Tooling Assembly for Composite Layup Alignment
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Solution Overview
Problem
Traditional tooling assemblies for forming composite components, such as gas turbine engine airfoils, have complex closing processes that require specific bolt torqueing sequences, leading to increased processing time, operator skill requirements, and reduced yield due to potential pinching or ply buckling, especially when dealing with varying thicknesses of composite layups.
Innovation Solution
A tooling assembly featuring a forward and aft cam portion with curvilinear and angled surfaces, respectively, and a pivoting mechanism between tool segments, allowing for simplified closure and proper alignment, even with varying thicknesses, using a single fastener for closure and ensuring contact between tool segments to prevent pinching or gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bolt torqueing sequence is used to close tooling assembly, then proper alignment can be achieved, but processing time increases and operator skill requirements increase
Solution Approach 1:
The cam portions are pre-configured with specific geometric profiles (curvilinear and angled surfaces) that automatically guide the tool segments into proper alignment as they close. This preliminary geometric configuration eliminates the need for complex torqueing sequences during operation, reducing both time and skill requirements while maintaining alignment precision.
Solution Approach 2:
The cam portions act as intermediary elements between the fasteners and the tool segments. Instead of directly controlling segment alignment through multiple bolts, the cam portions translate fastener movement into controlled segment closure and alignment, simplifying the closing process while ensuring proper positioning.
2Manufacturing precision
If multiple bolts are used to close tooling assembly, then proper alignment can be achieved, but device complexity increases
Solution Approach 1:
The closing function is segmented between the cam portions and the fasteners. The cam portions handle the alignment and guidance function, while the fasteners provide the closing force. This segmentation allows each component to be simpler while collectively achieving proper alignment, reducing overall device complexity.
Solution Approach 2:
The cam portions serve multiple functions simultaneously: they guide alignment, control closure sequence, and ensure proper segment positioning. This multi-functionality eliminates the need for separate alignment mechanisms and multiple adjustment bolts, reducing device complexity while maintaining precision.
3Productivity
If traditional closing process is used, then tool segments can be closed, but pinching or gaps may occur in composite layup
Solution Approach 1:
The curvilinear profile of the follower surface on the cam portions creates a gradual, curved closure path for the tool segments. This curvature ensures uniform contact and pressure distribution across the composite layup during closing, preventing pinching and gaps while maintaining high closing speed and reliable defect-free assembly.
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
The tooling assembly simplifies the closing process, reduces operator skill requirements, and ensures proper alignment and compaction of composite components, improving the quality of formed parts by accommodating varying thicknesses and preventing defects like pinching or gaps.
Implementation Method 1
The forward cam portion defines a follower surface, and at least a portion of the follower surface has a curvilinear profile. The first tool segment pivots with respect to the second tool segment.
Implementation Method 2
a rounded insert positioned between a head of the first fastener and the follower surface of the forward cam portion
Data Source
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AI summary
Tooling assemblies and methods for using a tooling assembly to shape an article are provided. For example, a tooling assembly (100) has a forward end (102) and an aft end (104) and comprises a first tool segment (106), a second tool segment (108), a forward cam portion (124) near the forward end, and an aft cam portion (126) near the aft end. The forward cam portion defines a follower surface (128), and at least a portion of the follower surface has a curvilinear profile. The aft cam portion defines a first surface (130) extending at a first angle (α) and a second surface (132) extending at a second angle (β). The first and second tool segments define a cavity (110) for shaping an article. An exemplary method comprises positioning an article preform within the cavity and inserting a fastener (152) within the aft end of the tooling assembly until the fastener is fully inserted within the tooling assembly.