Composite Drape Forming with Controlled Flange Translation
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Solution Overview
Problem
Uncontrolled compression during hot drape forming of composite structures often results in buckling or wrinkling of the plies, leading to defects in composite parts, particularly in aerospace applications.
Innovation Solution
A drape forming apparatus and method that includes a flange forming device with a pressurized bladder and controlled translation to ensure uniform and controlled pressure on the composite material, reducing the likelihood of buckling and wrinkling by using a flange forming device with a receiving slot and biasing device to manage the flange portion's draping over the forming tool's side surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite material is forced around the mandrel with vacuum bag or pressurized bladder device, then composite parts can be formed for use in aerospace industry, but uncontrolled compression can result in buckling or wrinkling of the plies within composite part
Solution Approach 1:
The system transitions from static vacuum/pressure application to dynamic controlled translation of the flange forming device. The flange forming device moves along the mandrel at controlled speeds, allowing progressive forming of the composite material while maintaining tension control, thereby preventing buckling and wrinkling during the forming process
Solution Approach 2:
The system controls multiple parameters including translation speed of the flange forming device, bladder pressure, and heating temperature. By dynamically adjusting these parameters during the forming process, the system maintains optimal tension and pressure conditions to prevent ply deformation while achieving the desired composite part geometry
2Productivity
If composite material is heated and forced around mandrel, then composite structure can be formed, but uncontrolled compression leads to buckling or wrinkling
Solution Approach 1:
The flange forming device prepares the composite material by applying controlled tension and positioning before the main forming action occurs. The device pre-stretches and positions the material on the mandrel, ensuring proper alignment and tension distribution before vacuum/pressure forming begins, which prevents defects during high-speed production
Solution Approach 2:
The system monitors forming parameters including material tension, bladder pressure, and translation speed during the process. This feedback allows real-time adjustments to maintain optimal forming conditions, preventing buckling and wrinkling while maintaining high productivity through controlled, repeatable cycles
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
The solution enables the formation of composite structures with reduced defects, ensuring a more reliable, easier, and defect-free process by maintaining controlled pressure and tension during the forming process.
Implementation Method 1
a pressurized bladder configured to extend over the forming tool and the upper plate of the flange forming device. The pressurized bladder is configured to force the flange portion against the at least one side forming surface
Implementation Method 2
Hot drape forming typically includes heating one or more plies of flat pre-impregnated (i.e., prepreg) composite material
Data Source
AI summary
A drape forming apparatus for that includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material over the upper forming surface. The apparatus includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot receives a flange portion of the layer of composite material, and the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus includes a pressurized bladder that extends over the forming tool and the upper plate. The pressurized bladder forces the flange portion against the side forming surface as the flange forming device translates relative to the forming tool.