Composite Connecting Rod Manufacturing with Localized Overthickness
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Solution Overview
Problem
The existing methods for manufacturing composite connecting rods with localized extra thickness are costly and complex, requiring layer separation and insertion of new woven fibers, making industrialization challenging.
Innovation Solution
A method involving the use of a mandrel for alternating braided and wound reinforcing fiber layers, followed by resin injection and curing, with machining to form interfaces for mechanical pins, simplifies the process and reduces costs by combining braiding and winding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layers of woven fibers are separated and new layers are inserted to increase local thickness, then the local thickness of the composite material is significantly increased, but the manufacturing process becomes costly and complex
Solution Approach 1:
The mandrel is designed with a localized protrusion before the manufacturing process begins. This protrusion serves as a pre-positioned form that guides the fiber placement and automatically creates the desired localized thickness increase without requiring subsequent layer separation or insertion operations. The protrusion is prepared in advance and remains throughout the fiber winding process.
Solution Approach 2:
The mandrel with its localized protrusion acts as an intermediary tool that translates the desired thickness variation into the final composite structure. The protrusion mediates between the uniform fiber winding process and the non-uniform thickness requirement, allowing simple continuous winding to produce complex thickness profiles.
2Manufacturing precision
If layers of woven fibers are separated and new layers are inserted to increase local thickness, then the local thickness is increased, but the industrialization of the process becomes challenging
Solution Approach 1:
The mandrel with pre-formed localized protrusion enables continuous fiber winding without interruption or complex manipulation. This preliminary preparation of the mandrel geometry allows the entire process to be automated and scaled for industrial production, eliminating the need for manual layer separation and insertion operations that hinder industrialization.
Solution Approach 2:
The fiber winding process continues uninterrupted around the mandrel with localized protrusion. The protrusion maintains the continuity of the winding operation while automatically creating the thickness variation, allowing for efficient, continuous manufacturing suitable for industrial-scale production.
3Ease of manufacture
If alternating braided and wound fiber layers are applied using a mandrel, then the manufacturing cost is reduced and industrialization is enabled, but the process requires precise coordination of multiple fiber application methods
Solution Approach 1:
The fiber reinforcement is segmented into two distinct application methods: braided fibers applied over the entire mandrel length and wound fibers applied selectively at reinforcing portions. This segmentation allows each method to be optimized for its specific function while being coordinated through the mandrel geometry.
Solution Approach 2:
Different fiber application methods are used in different locations: braided fibers provide general reinforcement along the entire length, while wound fibers provide localized thickness increase at specific reinforcing portions. The mandrel with localized protrusion ensures that wound fibers are deposited only where needed, creating local quality variations in the composite structure.
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 allows for the efficient and cost-effective manufacturing of connecting rods with varying thicknesses along their axis, enabling industrial-scale production with improved mechanical properties.
Implementation Method 1
injecting and curing resin into the braided and coiled fiber layers to establish a cohesion rigidly binding the braided layers to the coiled layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a process for manufacturing a connecting rod (19) made of a composite having one end in the form of a clevis (21). According to the invention, a layer (16a-16e) of reinforcing fibres (14) braided around a mandrel (5) is applied by a braiding machine (12) over the entire length of the mandrel (5); a layer (17a-17d) of reinforcing fibres is then applied by a winding machine around the end (7)(5) corresponding to the clevis (21); other layers of braided fibres (16a-16e) and wound fibres (17a-17d) are applied alternately until constituting a fibre (14) thickness sufficient for the clevis (21) to be formed. Resin is then injected into the various layers (16a-16e, 17a-17d) of braided and wound fibres, the resin then being cured, and the end comprising the wound layers (17a-17d) is machined in order to form thereat the clevis (21).