Composite Feature Forming for Precise Embossments Without Machining
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Solution Overview
Problem
Forming accurate and precise features, such as embossments and countersinks, in composite components like ceramic matrix composite (CMC) and polymer matrix composite (PMC) materials is challenging, often requiring additional material and labor due to post-processing machining, which weakens the composite.
Innovation Solution
A method involving depositing composite material on a base tool, using a feature forming tool with inserts to press the material into recesses, and processing it to form features without machining, supported by a frame or bagging for processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If features are machined in composite components after processing, then accurate and precise features can be formed, but the composite material is weakened and additional material is required
Solution Approach 1:
The feature forming tool is incorporated into the composite component tooling assembly before the composite material is deposited. The tooling assembly includes recesses that define the desired feature geometry. By performing the feature formation action preliminarily - during the composite material fabrication process rather than after - the material is shaped into the final feature geometry during deposition, eliminating the need for subsequent machining that would weaken the material.
Solution Approach 2:
The feature forming tool acts as an intermediary element between the composite material and the final feature geometry. The tool includes forming members with feature-defining surfaces that contact and shape the composite material during deposition. This intermediary tooling approach allows precise feature formation through material displacement into tool-defined recesses rather than through post-processing removal, preserving material strength.
2Manufacturing precision
If features are machined in composite components, then precise features are achieved, but additional composite material is required to provide adequate machining area
Solution Approach 1:
The feature geometry is preliminarily defined by recesses in the feature forming tool before composite material deposition. The composite material is deposited directly onto the tooling assembly and shaped by the tool's recesses during the deposition process itself. This preliminary action eliminates the need for additional material that would otherwise be required to provide machining area for post-processing operations.
Solution Approach 2:
The feature formation process is merged with the composite material deposition process. The feature forming tool is integrated into the tooling assembly used for depositing the composite material, allowing both the composite component and its features to be formed simultaneously in a single operation, rather than requiring separate machining operations that would consume additional material.
3Manufacturing precision
If features are machined after composite component processing, then accurate features are formed, but labor and material costs increase
Solution Approach 1:
The feature formation operation is merged with the composite material deposition operation. The feature forming tool is incorporated into the tooling assembly used for depositing composite material, allowing both the composite component and its features to be formed simultaneously. This consolidation eliminates the need for separate post-processing machining operations, reducing both labor and material costs while maintaining feature accuracy.
Solution Approach 2:
Feature formation is performed preliminarily during the composite material deposition process rather than after component processing. The feature forming tool shapes the composite material into final feature geometry during deposition, eliminating the need for costly post-processing machining operations while ensuring accurate feature formation.
Data Source
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Figure 2
Figure 3~3B
AI summary
Various methods and assemblies are provided for producing composite components (90) having formed in features. For example, a method may comprise depositing a composite material (102) on a base tool (100,200,300,400); deploying a feature forming tool (110,210,30,410,510) to press the composite material (102) into one or more recesses (104,204,304); and processing the composite material (102) with the feature forming tool (110,210,30,410,510) pressing the composite material (102) into the one or more recesses (104,204,304). The processed composite material (102) forms a green state composite component. The feature forming tool (110,210,30,410,510) comprises one or more forming members (214), supported by a frame (212), for forming one or more features of the composite component (90). The method also may include sealing a bag (125) around the composite material (102) before deploying a feature forming tool (110,210,30,410,510) and removing the feature forming tool (110,210,30,410,510) and the bag (125) after processing the composite material (102).