Composite Braided Strut Rod with Variable Fiber Density
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Solution Overview
Problem
Existing methods for manufacturing mechanical components like strut rods from composite materials result in oversized components due to uniform fiber thickness, leading to unnecessary mass and inefficiency in material distribution under varying mechanical stress.
Innovation Solution
A process that varies the density of longitudinal fibers across different regions of the component by using braiding and deposition techniques, where the mandrel is offset radially during braiding to concentrate more fibers in stress-prone areas, allowing for a greater thickness in one region and a smaller thickness in another, achieved by using a braiding machine with coils of different gauges and strategically placing them on the ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform thickness of reinforcing fibers is used throughout the mandrel, then manufacturing simplicity is maintained, but the component becomes oversized with unnecessary mass in low-stress regions
Solution Approach 1:
The patent applies local quality by varying the density of longitudinal fibers according to the stress distribution in different regions of the component. High-stress regions receive higher fiber density while low-stress regions receive lower density, optimizing the component's weight and performance by matching material distribution to actual structural needs rather than using uniform thickness throughout.
2Ease of manufacture
If the mandrel is positioned concentrically with the braider axis, then the braiding process is simpler, but the fiber density cannot be optimized for specific stress regions
Solution Approach 1:
The patent employs asymmetry by deliberately positioning the mandrel off-center relative to the braider's central axis. This asymmetric positioning allows the braiding process to deposit longitudinal fibers with non-uniform density around the mandrel circumference, creating regions of higher fiber concentration in areas that require enhanced structural strength while maintaining a controlled and reproducible manufacturing process.
3Strength
If additional reinforcing elements are distributed unevenly around the perimeter, then fiber density optimization is achieved, but the braiding device complexity increases
Solution Approach 1:
The patent solves the complexity issue by introducing a positional dimension - offsetting the mandrel along the radial axis of the braider. This dimensional change allows uniform fiber feed from the braiding device to naturally create non-uniform fiber density distribution on the mandrel surface, achieving structural optimization without modifying the braiding device itself or adding complex control mechanisms for differential fiber delivery.
Data Source
AI summary
The invention relates to a process for manufacturing a mechanical member, comprising several operations in which plies of reinforcing fibres are braided, with a braiding machine, and the braided plies are deposited on a mandrel (11). Each operation comprises the braiding of a ply and the deposition thereof by moving the mandrel (11) along a central axis of the braiding machine. The various braided plies, which are superposed, each comprise longitudinal fibres (12, 12G) parallel to a main direction of the mandrel (11) and inclined roving fibres. At least one operation is designed to form and deposit a braided ply having, at least in a cross section of the member, a longitudinal fibre density that differs depending on whether an angular region (S1), or another angular region (S2) of the same extent around the centre of mass (G) of the mandrel (11) in the cross section in question, is considered. The invention applies to the manufacture of structural components in the aeronautical field.