Cam-Closing Tooling Assembly for Composite Layup Alignment
Find Innovative SolutionsGenerate Solutions
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 design featuring a forward and aft cam portion with curvilinear and angled surfaces, along with pivoting tool segments and fasteners, simplifies the closing process by ensuring proper alignment and accommodating varying thicknesses, allowing for efficient compaction and shaping of composite components without pinching or gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bolt torqueing sequence is used to close the tooling assembly, then the segments can be secured together, but the 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 the closing force is applied. This preliminary geometric configuration eliminates the need for operators to follow complex torqueing sequences, as the alignment action is built into the cam mechanism itself.
Solution Approach 2:
The cam closing mechanism is self-aligning through its geometric design. As the cam portions engage and close, the curvilinear and angled surfaces automatically guide the tool segments into correct alignment without requiring external control or operator intervention. The system serves itself by using the closing force to simultaneously achieve both closure and alignment.
2Reliability
If traditional bolt torqueing sequence is used to close the tooling assembly, then the segments can be secured together, but the operator skill requirements increase
Solution Approach 1:
The cam portions are designed with self-aligning geometric profiles that automatically ensure proper tool segment alignment during closing. This eliminates the need for operators to possess specialized skills in following complex torqueing sequences, as the alignment function is inherently built into the cam mechanism's geometry.
Solution Approach 2:
The cam portions are pre-configured with specific geometric profiles (curvilinear and angled surfaces) that automatically guide the tool segments into proper alignment as the closing force is applied. This preliminary geometric configuration eliminates the need for operators to follow complex torqueing sequences, as the alignment action is built into the cam mechanism itself.
3Reliability
If traditional tooling assembly closing process is used, then the segments can be secured together, but pinching or ply buckling may occur
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 the closing force is applied. This preliminary geometric configuration eliminates the need for operators to follow complex torqueing sequences, as the alignment action is built into the cam mechanism itself.
Solution Approach 2:
The cam portions are designed with non-uniform geometric profiles (curvilinear and angled surfaces) that create varying contact pressures across different regions of the tool segments. This localized pressure distribution ensures uniform closing force application, preventing pinching or ply buckling while maintaining secure closure.
4Adaptability or versatility
If traditional tooling assembly is used with varying thickness composite layup, then the assembly can accommodate different thicknesses, but proper alignment becomes difficult to ensure
Solution Approach 1:
The cam portions are designed with non-uniform geometric profiles (curvilinear and angled surfaces) that create varying contact pressures across different regions of the tool segments. This localized pressure distribution ensures uniform closing force application, preventing pinching or ply buckling while maintaining secure closure.
Solution Approach 2:
The cam mechanism utilizes geometric parameter variations (curvilinear and angled surfaces) to dynamically adjust the closing force distribution. As the tool segments close, the cam profiles automatically modify the contact pressure parameters to accommodate varying layup thicknesses while maintaining proper alignment throughout the closing process.
Data Source
AI summary
Tooling assemblies and methods for using a tooling assembly to shape an article are provided. For example, a tooling assembly has a forward end and an aft end and comprises a first tool segment, a second tool segment, a forward cam portion near the forward end, and an aft cam portion near the aft end. The forward cam portion defines a follower surface, and at least a portion of the follower surface has a curvilinear profile. The aft cam portion defines a first surface extending at a first angle and a second surface extending at a second angle. The first and second tool segments define a cavity for shaping an article. An exemplary method comprises positioning an article preform within the cavity and inserting a fastener within the aft end of the tooling assembly until the fastener is fully inserted within the tooling assembly.