Composite Edge Ply Compensation for Resin Migration
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Solution Overview
Problem
Existing methods for manufacturing composite parts from prepreg fibres suffer from edge effects during curing, leading to dimensional inaccuracies and increased production costs due to material wastage and extended cycle times, as the resin migrates away from the periphery, causing the part to lose height at the edges.
Innovation Solution
A method that involves covering the edges with additional plies before curing to compensate for resin migration, ensuring these plies are cured simultaneously with the rest of the part, allowing for minimal material addition and reduced cycle times by incorporating these plies into the edge zones to be removed post-curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dimensions of the blank are increased to account for edge effects, then the final part dimensions can be achieved after machining, but the quantity of material used and machining time increase
Solution Approach 1:
The method applies preliminary action by adding extra plies during the lay-up phase before curing to pre-compensate for the resin migration that will occur during the curing process. This preliminary compensation ensures that after curing and subsequent machining, the final part achieves the desired dimensions without requiring excessive material in the blank.
Solution Approach 2:
The invention applies local quality by adding plies specifically at the peripheral zones where edge effects occur, rather than uniformly increasing the dimensions of the entire blank. This targeted approach compensates for resin migration only where it happens (at the edges) while maintaining optimal material usage in the central portion of the part.
2Manufacturing precision
If the dimensions of the blank are increased to account for edge effects, then the final part dimensions can be achieved after machining, but the machining time increases
Solution Approach 1:
By performing the compensation for edge effects during the lay-up phase rather than adding material after curing, the method reduces the amount of material that needs to be removed during machining. This preliminary action significantly decreases machining time while still achieving the required final dimensions.
3Manufacturing precision
If additional plies are added at the edge to correct geometric defects, then the part dimensions are improved, but the production cycle time increases due to multiple curing phases
Solution Approach 1:
The invention merges the compensation for edge effects with the main curing cycle by incorporating the additional plies into the original lay-up. This allows both the central and peripheral zones to be cured simultaneously in a single curing phase, eliminating the need for separate curing cycles that would extend production time.
Solution Approach 2:
The method performs the compensation action during the initial lay-up phase before curing begins, rather than attempting to correct dimensions after curing. This preliminary preparation ensures that the part achieves correct dimensions through a single curing cycle, avoiding extended production times associated with multiple curing and re-inspection phases.
4Manufacturing precision
If the quantity of material is increased to compensate for edge effects, then the final part dimensions can be achieved, but the raw material costs increase
Solution Approach 1:
The invention optimizes material usage by applying the compensation strategy locally only at the peripheral zones where edge effects occur, rather than increasing material throughout the entire blank. This targeted approach minimizes raw material costs while achieving the required final dimensions.
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 approach effectively limits edge effects while maintaining the dimensions of the finished part close to the original blank, optimizing material usage and shortening production cycles by integrating additional plies into the machining process without altering the part's structure.
Implementation Method 1
During curing, the resin tends to migrate away from the periphery of the part, so that the height of the part tends to decrease from the middle towards the sides thereof
Implementation Method 2
A method for obtaining a part made of a composite of fibres embedded in a resin matrix which comprises a portion called a body and a portion called an edge, the method comprising a first step of stacking plies of fibres and a second step of curing the plies, characterized in that, prior to the curing step, the method further comprises the step of covering the edge with at least one additional ply, in order to compensate for the migration of the resin during curing
Data Source
AI summary
The invention relates to method for obtaining a part made of a composite of fibers embedded in a resin matrix which comprises a body and an edge. The method comprises a first step of stacking plies of fibers and further comprises a step of curing the plies. The method further comprises prior to the curing step, the step of covering the edge with at least one additional ply, in order to compensate for the migration of the resin during curing.