Composite Feature Forming via Base Tool Recesses
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Solution Overview
Problem
Forming accurate and precise features in composite components, such as embossments, countersinks, and counterbores, without weakening the material is challenging, as existing methods often require additional material and machining, which can be labor-intensive and costly.
Innovation Solution
A method and assembly for forming features in composite components by using a base tool with recesses and a feature forming tool that deposits and processes composite material, allowing features to be formed during the fabrication process rather than after, using a combination of tools and techniques like tooling apertures and feature forming tools to guide and press the material into defined shapes.
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 additional composite material is required and the material is weakened by cutting through layers
Solution Approach 1:
The feature geometry is preliminarily defined by recesses in the base tool before composite material deposition. The composite material is laid up and cured around these pre-defined recesses, forming features such as countersinks and counterbores during the fabrication process itself, rather than machining them afterward. This preliminary configuration of the tooling ensures the feature shape is established before the material is fully processed.
Solution Approach 2:
A feature forming tool with inserts acts as an intermediary between the base tool and the composite material. The inserts on the feature forming tool define the feature geometry and guide the composite material into the recesses of the base tool, enabling precise feature formation without direct machining of the cured composite. This intermediary tooling system transfers the feature geometry to the composite material during deposition.
2Manufacturing precision
If features are machined in composite components after processing, then features can be formed accurately, but additional labor and material costs are incurred
Solution Approach 1:
The feature formation process is merged with the composite material fabrication process. The base tool with recesses and the feature forming tool with inserts work together during material deposition and curing to create both the composite component and its features in a single integrated operation. This eliminates the separate post-processing machining step, combining two operations into one.
Solution Approach 2:
The feature geometry is preliminarily defined by recesses in the base tool and inserts on the feature forming tool before composite material deposition. This preliminary configuration ensures that features are formed during the primary fabrication process rather than requiring separate post-processing operations, improving manufacturing efficiency.
3Ease of manufacture
If additional composite material is provided for machining area, then features can be machined, but material usage increases
Solution Approach 1:
The base tool has recesses located at specific local positions where features are needed in the final component. The composite material is deposited and formed only in these specific locations defined by the recesses, rather than providing excess material throughout the entire component. This local configuration of the tooling ensures material is used only where feature geometry is required.
Data Source
Figure 1
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); aligning an aperture forming tool (132,332)with a tooling aperture (130.330) (330) in the base tool (100,200,300,400); inserting the aperture forming tool (132,332) through the composite material (102) to form an aperture (128) in the composite material (102); deploying a feature forming tool (110,210,310,410) 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 (110,210,310,410) in contact with the composite material (102). In some embodiments, the feature forming tool (110,210,310,410) includes a stem (312) extending through the composite material (102) and into the base tool (100,200,300,400), as well as a feature forming head (218, 436, 514) that is brought into contact with and processed with the composite material (102). In other embodiments, a tooling assembly (412, 500) holds a pin (414) in place during processing to fix the pin in the composite component (90).