Composite Airfoil Ply Stacking with Hybrid Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing composite airfoils face challenges in balancing efficiency and precision, particularly in the integration of automated and manual processes, which can compromise the strength and complexity of the assembly.
Innovation Solution
A hybrid manufacturing method is employed, combining automated processes for larger sections and manual processes for smaller, harder-to-reach areas, utilizing different sets of plies with varying fiber lengths and materials to construct a composite airfoil, ensuring both efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated processes are used for stacking plies, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The airfoil is divided into multiple sections (first section, second section, third section) with different stacking requirements. Automated processes are applied to the first section where precision is less critical, while manual processes are used for the second and third sections where higher precision is needed for complex geometries and hard-to-reach areas.
Solution Approach 2:
Different manufacturing approaches are applied to different regions of the airfoil based on local requirements. The first section uses automated stacking for efficiency, while the second and third sections use manual stacking to achieve the required precision for complex shapes and tight tolerances in hard-to-reach areas.
2Manufacturing precision
If manual processes are used for stacking plies, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The airfoil manufacturing process is segmented into multiple sections, with manual processes reserved for specific sections (second and third sections) where precision is critical, while automated processes handle the first section to maintain overall productivity.
Solution Approach 2:
Manual stacking is applied locally to sections requiring high precision (second and third sections with complex geometries), while automated stacking is used in sections where precision requirements are lower, optimizing the balance between precision and productivity for each local region.
3Ease of manufacture
If hybrid manufacturing process is used, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct sections with different methods (automated for first section, manual for second and third sections), allowing each segment to be optimized independently while maintaining overall manufacturing flexibility and ease of implementation.
Data Source
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AI summary
A method (380) of forming an assembly (100). The assembly (100) having a stack of plies (177) and an airfoil portion (110). The airfoil portion has an outer wall (172) extending between a root (118) and a tip (120) in a spanwise direction (Sd), and between a leading edge (114) and a trailing edge (116). The assembly (100) has a first set of plies (140) and a second set of plies (142). The first set of plies (140) form at least a portion of the airfoil portion (110).