Composite Drape Forming with Tension-Controlled Release Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional drape forming processes for composite materials are inefficient and prone to buckling or wrinkling, especially for complex shapes like aircraft parts, limiting their application in construction.
Innovation Solution
The system employs a forming mandrel with a non-planar surface, a flexible and resilient charge support membrane, a membrane suspension device, and a release structure, along with a vacuum source to apply varying vacuum levels, allowing the composite material to be deformed without significant buckling or wrinkling by controlling tension and deformation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drape forming processes are used to form composite parts with non-planar surface contours, then the process can be implemented with simple equipment, but the process induces undesired buckles and wrinkles within the layered charge
Solution Approach 1:
The charge support structure is configured in advance to maintain the layered charge in a tensioned, wrinkle-free state before forming begins. The support membrane is pre-tensioned and positioned to contact the charge at strategic locations, preventing buckles and wrinkles from forming during the subsequent deformation process.
Solution Approach 2:
A charge support structure acts as an intermediary between the forming mandrel and the layered charge. This support structure temporarily sustains the charge during forming, distributing forces evenly and preventing direct contact between the charge and mandrel surfaces that would cause surface defects.
2Productivity
If drape forming is used to create complex shapes efficiently, then productivity increases, but buckles and wrinkles occur during deformation
Solution Approach 1:
The system prepares the charge support structure in advance with appropriate tension and positioning, enabling rapid forming without the need for slow, careful manual manipulation. The pre-configured support allows the charge to be deformed quickly while maintaining surface quality.
Solution Approach 2:
The charge support structure is designed to be dynamic rather than static, allowing it to adapt its support characteristics during the forming process. The support membrane can flex and adjust its tension distribution as the charge deforms, maintaining optimal support conditions throughout the rapid forming operation.
3Shape
If layered charges are deformed to non-planar shapes, then complex composite parts can be manufactured, but buckles and wrinkles are induced in the charge
Solution Approach 1:
The charge support structure serves as a mediating element between the forming mandrel and the layered charge, allowing complex shapes to be formed without direct contact that would cause surface defects. The support structure distributes deformation forces evenly across the charge.
Solution Approach 2:
The charge support structure utilizes a flexible membrane that can conform to complex mandrel geometries while maintaining tension across the layered charge. This thin film approach provides uniform support that prevents buckles and wrinkles even when forming complex three-dimensional shapes.
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 enables defect-free drape forming of composite materials, allowing for the creation of complex shapes without buckling or wrinkling, thereby improving the efficiency and accuracy of composite part construction.
Implementation Method 1
a vacuum source configured to selectively apply a vacuum to the enclosed volume
Implementation Method 2
The release structure operatively couples the charge support membrane to the membrane suspension device when a tension on the peripheral region of the charge support membrane is less than a threshold tension and releases the charge support membrane from the membrane suspension device when the tension is greater than the threshold tension
Data Source
AI summary
Systems and methods for drape forming a charge of composite material are disclosed herein. The systems include a forming mandrel, a charge support structure, a flexible and resilient forming membrane, a base, and a vacuum source. The charge support structure includes a flexible and resilient charge support membrane, a membrane suspension device, and a release structure. The release structure operatively couples the charge support membrane to the membrane suspension device when a tension on a peripheral region of the charge support membrane is less than a threshold tension and releases the charge support membrane from the membrane suspension device when the tension is greater than the threshold tension. Alternatively, and in place of the charge support structure, the systems include a means for supporting the charge of composite material. The methods include methods of drape forming a charge of composite material.