Co-bonded Tab Alignment for Composite Tooling Precision
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Solution Overview
Problem
The manufacturing of tooling plates for composite structures is time-consuming and prone to errors, leading to inconsistencies such as voids, delamination, and wear, which can result in composite parts with undesired shapes or surface properties, necessitating rework or discard.
Innovation Solution
A method and apparatus involving a tooling plate co-bonded with a tab having pre-machined alignment features, which are positioned and bonded during the curing process to form a tooling device, reducing the need for post-curing operations and minimizing inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment features are machined in the tooling plate after curing, then the tooling plate can be formed with desired shape, but the manufacturing process becomes time-consuming and prone to errors causing inconsistencies
Solution Approach 1:
The alignment features are pre-machined in the tab before bonding to the tooling plate, rather than machining them after the tooling plate is cured. This preliminary action eliminates post-curing operations, reducing manufacturing time and the risk of inconsistencies such as voids, delamination, and foreign object debris that can occur during post-curing machining operations.
2Ease of manufacture
If operations are performed on the tooling plate after curing, then alignment features can be created, but inconsistencies such as voids, delamination, and cracks occur
Solution Approach 1:
The tab is pre-machined with alignment features before bonding to the tooling plate. This allows alignment features to be created in a controlled environment before the bonding process, eliminating the risk of voids, delamination, and cracks that occur when machining after curing. The tab serves as a sacrificial carrier for the alignment features.
Solution Approach 2:
The alignment features are separated from the tooling plate by being machined in the tab instead. This segmentation allows the alignment features to be created independently in the tab, which is then bonded to the tooling plate, avoiding the harmful effects of post-curing machining on the tooling plate itself.
3Productivity
If a traditional tooling plate is used, then the composite part can be formed, but the tooling plate requires rework or discard due to wear and inconsistencies
Solution Approach 1:
The alignment features are segmented from the tooling plate and placed in the tab. This segmentation protects the tooling plate from wear and damage during machining operations, as all machining is performed on the tab. The tooling plate itself remains intact and can be reused without rework, extending its service life and reducing the need for discard.
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 enhances the efficiency and accuracy of tooling device manufacturing, decreases the risk of inconsistencies, and allows for more precise alignment features, resulting in composite parts with desired shapes and surfaces, reducing rework and increasing tooling device longevity.
Implementation Method 1
a first number of layers of composite material is laid up on a tool... a second number of layers of composite material is laid up... The first number of layers of composite material, the second number of layers of composite material, and the tab are co-bonded to form the tooling device
Data Source
AI summary
A method and apparatus for forming a composite part. An apparatus comprises a tooling plate, a tab co-bonded with the tooling plate, and a group of alignment features associated with the tab. The tooling plate is configured for use with a tool to form a composite part. The group of alignment features is configured to position the tooling plate with respect to the tool used to form the composite part.