Composite Drill Template Machining in the As-Cured Shape
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Solution Overview
Problem
Composite parts, especially large ones, tend to deform after being removed from a cure tool, leading to accuracy issues in machining operations and requiring post-machining shimming, which complicates assembly and predictive assembly in manufacturing.
Innovation Solution
A system and method for post-cure processing that includes a tool with a sacrificial portion and a drill template, allowing machining operations to be performed on the composite workpiece while it is still on the tool, reducing deformation and enabling accurate machining by aligning drilling locations with the sacrificial portion, and generating a digital model for precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite parts are removed from the cure tool for machining operations, then the parts can be processed, but the parts deform leading to accuracy issues
Solution Approach 1:
The patent applies preliminary action by performing machining operations on the composite part while it is still mounted on the cure tool, before the part is removed and potentially deforms. The drill template is positioned on the tool surface to guide drilling operations at the correct locations while the part maintains its cured shape, ensuring machining accuracy is achieved before any deformation can occur.
2Manufacturing precision
If machining operations are performed while the composite part is on the tool, then machining accuracy is improved, but the tool structure becomes more complex
Solution Approach 1:
The patent introduces a drill template as an intermediary element that bridges the need for accurate machining locations and the existing tool structure. The template includes positioning features that interface with the cure tool and drilling features that guide the drill bits, allowing accurate machining to be performed on the mounted part without requiring complex modifications to the base tool itself.
3Manufacturing precision
If post-machining shimming is performed to correct deformation, then assembly accuracy is improved, but the assembly process becomes more complex
Solution Approach 1:
The patent eliminates the need for post-machining shimming by performing all necessary machining operations while the part is still on the tool in its accurate as-cured configuration. By completing machining before removal and potential deformation occurs, the part maintains its precision without requiring subsequent corrective shimming operations, thereby simplifying the overall assembly process.
Data Source
AI summary
A system for post-cure processing a composite workpiece includes a tool. The tool includes a tool surface. The tool surface supports the composite workpiece located on the tool. The system also includes a drill template. The drill template defines a drilling location for drilling a hole through the composite workpiece while the composite workpiece is on the tool.