Composite Coupling Machining Portion Fiber Segmentation
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Solution Overview
Problem
Existing composite material couplings face challenges in adapting to varied geometrical specifications without compromising mechanical integrity, as machining to fit exact surfaces often cuts through fibers, making them weaker and less effective.
Innovation Solution
A coupling design featuring a structural portion with a main fiber structure and distinct machining portions with separate fiber structures, allowing for precise machining without intersecting the main fiber structure, ensuring the coupling's mechanical integrity and adaptability to different assembly configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If machining is performed on the coupling to match surfaces of adjacent parts, then the coupling can be adapted to varied geometrical specifications, but the machining cuts through the fibers of the preform, compromising the mechanical integrity of the coupling
Solution Approach 1:
The coupling is divided into two distinct portions: a structural portion with a main fiber structure that provides mechanical integrity, and a machining portion with a first fiber structure that is dedicated to being machined. This segmentation allows the machining portion to be adapted to various geometrical specifications while the structural portion remains intact and maintains the coupling's mechanical strength.
Solution Approach 2:
Different portions of the coupling are assigned different fiber structures with different orientations. The structural portion has a main fiber structure optimized for mechanical strength, while the machining portion has a first fiber structure that is easier to machine. This local differentiation allows each portion to fulfill its specific function without compromising the other.
2Manufacturing precision
If a different mold is made for each assembly configuration, then the coupling can match exact surfaces, but the technique is not economically viable
Solution Approach 1:
The coupling is segmented into a structural portion and a machining portion. The machining portion is designed to be machined after the coupling is manufactured using standard molds. This approach eliminates the need for custom molds for each assembly configuration, as the machining portion can be adapted through machining operations rather than requiring different molds, thereby improving economic viability while maintaining surface matching precision.
3Shape
If the preform is deformed to match the outlines of the mold in the corners of the flange, then the coupling can fit the mold geometry, but the radius of curvature is too small, making the corners zones rich in polymer and mechanically weaker
Solution Approach 1:
The coupling is divided into a structural portion that maintains the main fiber structure for mechanical strength, and a machining portion that can be shaped and machined to fit the mold geometry including corner regions. This segmentation allows the machining portion to conform to the mold outlines without requiring excessive deformation of the main fiber structure, thereby preventing polymer-rich weak zones while maintaining overall shape conformity.
Data Source
AI summary
A coupling made of composite material including a polymer matrix reinforced by a fiber structure is disclosed. The coupling includes a structural portion reinforced by a main fiber structure, and a first machining portion reinforced by a first fiber structure that is distinct from the main fiber structure. The matrices of the structural portion and of the first machining portion are identical. The first machining portion is situated on at least a fraction of the main face of the structural portion and is machined in a first machining surface. There is no intersection between the first machining surface and the fibers of the main fiber structure.