Composite Integral Flange Forming via Segmented Tool
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Solution Overview
Problem
The formation of composite components with integral flanges, particularly in regions with bends, poses challenges due to discontinuous surfaces, leading to poor quality flanges in existing manufacturing methods.
Innovation Solution
A method and tool design that utilizes a forming assembly with radially movable forming elements and filler elements to create a continuous flange-forming surface, allowing for the deformation of a pre-form to form a substantially continuous integral flange by moving the forming assembly from a lay-up configuration to a forming configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circumferentially spaced movable sectors are used to form the flange, then the flange can be formed after layup, but the surface is discontinuous resulting in poor quality flange
Solution Approach 1:
The forming assembly is divided into multiple movable forming elements that can be independently actuated. These elements are arranged circumferentially around the mold and can move radially to form the flange. The segmentation allows the preform to be deformed progressively as each element moves, enabling flange formation after layup while maintaining control over the forming process.
Solution Approach 2:
Adjacent forming elements are designed to work together to create a continuous flange surface. The elements are positioned and sized so that when they move radially outward, their flange-forming surfaces merge to form a continuous circumferential surface, eliminating the discontinuities that would result from spaced sectors.
2Ease of manufacture
If forming elements are moved radially outward to form the flange, then the flange can be formed, but gaps appear between circumferentially spaced elements
Solution Approach 1:
Different regions of the forming assembly have different functions: the main forming elements provide the primary flange-forming surface, while filler elements specifically address the gap regions between adjacent forming elements. The filler elements are positioned to fill the circumferential gaps and provide local material support, ensuring continuous surface formation in the gap regions.
3Manufacturing precision
If a continuous flange-forming surface is created, then high quality flanges can be produced, but the tool complexity increases with multiple forming and filler elements
Solution Approach 1:
The forming elements serve multiple functions: they provide the primary flange-forming surface when moved radially, and they also define the circumferential spacing that guides the filler elements. The same basic element structure is used throughout the assembly, providing universality and reducing the variety of different components needed, thereby managing complexity.
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 enables the production of high-quality, continuous flanges in composite components by ensuring a continuous flange-forming surface, improving the manufacturing process for components like gas turbine casings.
Implementation Method 1
movement of the forming assembly from the layup configuration to the forming configuration causes a region of the pre-form to deform between the continuous flange-forming surface and a counteracting forming surface to form the integral flange of the component
Data Source
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AI summary
There is disclosed a method of forming a composite component having a curved body and an integral flange from a pre-form (200) using forming apparatus comprising: a tool (102) comprising a curved body portion (104) having a lay-up surface (110) and a forming assembly (105) comprising a plurality of forming elements (106) each having a lay-up surface (120) and a primary flange-forming surface (122); and a plurality of filler elements (107) each having a secondary flange-forming surface (156). The method comprises: providing a pre-form (200) over the lay-up surfaces (110, 120) of the curved body portion 104 and the forming elements (106) of the tool (102) in a layup configuration of the forming assembly (105); moving the forming elements (106) radially outwardly from the layup configuration to respective forming positions so that the forming elements (106) are circumferentially spaced apart from one another to form gaps therebetween; moving the filler elements (107) radially outwardly to respective forming positions in the circumferential gaps between the forming elements (106) so that the primary and secondary flange-forming surfaces (122, 156) form a substantially continuous flange- forming surface in a forming configuration of the forming assembly (105). Movement of the forming assembly (105) from the layup configuration to the forming configuration causes a region of the pre-form (200) to deform between the continuous flange-forming surface and a counteracting forming surface to form the integral flange of the component.