Cantilevered Compression Tool for Composite Layup
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Solution Overview
Problem
The manufacturing of gas turbine engine components, particularly composite ducts, faces challenges in achieving uniform compressive forces and precise contour following during the layup process, leading to issues like porosity, ply waviness, and thickness variation, which affect the robustness and integrity of the final product.
Innovation Solution
The use of a layup tool with a bolt and guide pins system, combined with cantilevered compression tools and bridging tools, applies controlled compressive forces to distribute pressure evenly across the composite layup, ensuring proper alignment and curing of the composite article to form robust gas turbine engine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional compression tools are used for manufacturing composite ducts, then the manufacturing process is simple, but uniform compressive force distribution is difficult to achieve, leading to porosity and thickness variation
Solution Approach 1:
The compression tool is divided into multiple independent compression elements distributed around the composite layup perimeter. Each element can apply compressive force independently, allowing uniform distribution of force around the entire circumference of the duct, thereby eliminating porosity and thickness variation without requiring an overly complex monolithic tool design.
Solution Approach 2:
The compression tool integrates multiple functions into a single device: it combines the layup tool with compression tools that apply both radial and axial compressive forces simultaneously. This merging of functions achieves uniform compressive force distribution while maintaining reasonable device complexity, as the integrated tool applies multi-directional compression in one operation.
2Manufacturing precision
If simple compression tools are used, then the device complexity is low, but precise contour following during layup is difficult, affecting component robustness
Solution Approach 1:
The compression tools are designed with movable and adjustable components that can dynamically adapt to the contour of the composite layup. The compression elements can move radially and axially to follow the complex geometry of the duct, ensuring precise contour following throughout the curing process without requiring an excessively complex mechanical structure.
Solution Approach 2:
The compression tools act as intermediaries between the rigid mold and the composite layup. They transfer and distribute compressive forces uniformly across the layup surface while conforming to its contour, mediating the interaction between the tooling and the composite material to achieve both simplicity and precision.
3Reliability
If inadequate compressive force is applied, then the manufacturing process is simpler, but porosity and ply waviness occur, reducing structural integrity
Solution Approach 1:
The compression tools are positioned and pre-loaded before the composite curing process begins. This preliminary application of compressive force ensures that the layup is properly consolidated from the start, preventing porosity and ply waviness formation during the curing process, thereby ensuring structural integrity without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The compression tools maintain continuous compressive force throughout the entire curing process. This continuous application of pressure ensures that the composite layers remain firmly bonded and free of voids throughout curing, guaranteeing structural integrity while using a relatively simple sustained compression system rather than complex intermittent adjustment mechanisms.
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 method enhances the uniformity and robustness of composite gas turbine engine components by reducing porosity, ply waviness, and thickness variation, thereby improving the structural integrity and reducing scrap rates and the need for secondary machining operations.
Implementation Method 1
A spring member can be provided to urge the bolt along the bolt axis in a third direction away from the first tool portion in an installed position
Data Source
Figure 1
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Figure 3~4
AI summary
An assembly (60) and a method for forming a gas turbine engine (20) includes a layup tool (62) including a main body (MB) extending along a longitudinal axis (X) and a flange (68) extending radially from the main body (MB), the flange (68) defining an edge face (68E) slopes towards the main body (MB) to an axial face (68A). At least one compression tool (64) has a tool body (70) having a first tool section (72) and a second tool section (74) extending transversely from the first tool section (72). The first tool section (72) is translatable along a retention member (76) in a first direction (D1) substantially perpendicular to the edge face (68E) such that relative movement causes the second tool section (74) to apply a first compressive force (CI) on a composite article trapped between the axial face (68A) of the flange (68) and the second tool section (74).