Composite Flange from Braided Preform with Bias Tows
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Solution Overview
Problem
The design and manufacturing of flanges on cylindrical composite parts, particularly those made from triaxial braid, face challenges due to the inability of axial tows to deform and conform to larger diameters, leading to reduced structural properties and increased manufacturing complexity.
Innovation Solution
A preform sheet for composite components is created with a body section and a flange section, where the flange section includes two braided layers defined by bias tows extending from the body section, without axial tows, allowing for a reinforced flange structure that can be upturned or downturned without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If axial tows are included in the flange section of a triaxial braid, then the flange can be formed with continuous fiber reinforcement, but the axial tows cannot deform to conform to the larger diameter of the upturned flange, compromising structural integrity
Solution Approach 1:
The preform is divided into a body section with axial tows and a flange section without axial tows. This segmentation allows each section to have the appropriate fiber configuration for its specific function, enabling the flange to deform properly while maintaining structural integrity where axial reinforcement is needed.
Solution Approach 2:
Different sections of the preform have different fiber compositions - the body section contains axial tows for longitudinal strength while the flange section contains only bias tows for deformability. This local differentiation optimizes each region's properties for its specific structural requirements.
2Reliability
If axial tows are removed from the flange section, then the flange can be upturned without compromising structural properties, but the manufacturing process becomes more complex
Solution Approach 1:
The axial tows are removed from the flange section during preform fabrication before the braiding process begins. This preliminary action simplifies the subsequent braiding process and ensures the correct fiber configuration is established before manufacturing, rather than requiring complex post-processing.
Solution Approach 2:
Axial tows are extracted from the flange section of the preform, leaving only bias tows in that region. This extraction simplifies the flange section's structure, enabling it to deform properly during forming while reducing manufacturing complexity by eliminating the need to manage axial tows in the flange region.
3Ease of manufacture
If a single-layer flange structure is used, then the manufacturing process is simpler, but the bearing strength and hoop strength of the flange are insufficient
Solution Approach 1:
The flange section uses a composite structure with multiple braided layers having different bias orientations (e.g., ±45 degrees). This composite layering provides enhanced bearing strength and hoop strength while maintaining manufacturing simplicity, as the layers are integrated into a single preform component.
Solution Approach 2:
Instead of increasing flange strength by adding axial tows in the plane of the flange, the solution adds strength through multiple braided layers in the thickness dimension. This approach achieves superior mechanical properties while keeping the manufacturing process simple and integrated.
Data Source
AI summary
A preform sheet for a composite component comprises a body section and a flange section. The preform body section includes a plurality of axial tows braided with at least a plurality of first bias tows and a plurality of second bias tows. The preform flange section includes a first braided flange layer and a second braided flange layer. The first braided flange layer is defined by the first and second braided bias tows of the preform body section extending into the flange section. Neither the first nor second braided flange layers have axial tows.