Composite Flange Forming Tension Control
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Solution Overview
Problem
Manufacturing composite components with integral flanges from composite materials like Carbon Fibre Reinforced Polymer (CFRP) poses challenges, particularly in achieving a low curvature transition between the main body and the flange, as existing methods often result in forming defects such as out-of-plane wrinkles and ply misalignment due to the difficulty in pre-defining the shape on lay-up surfaces.
Innovation Solution
A method involving the application of fibre-reinforcement material on a tool with a main body and flange-forming portion to create a pre-form with a trailing ply that extends beyond the flange region, allowing relative movement between the flange-forming and main body portions to induce a tension force during forming, which helps in forming the flange while minimizing defects by promoting sliding movement and frictional contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a movable second portion is actuated to move radially outward to form the flange, then the flange can be formed, but out-of-plane wrinkles and ply misalignment occur in the transition region
Solution Approach 1:
The method applies a preliminary tension force to the pre-form in the transition region before the flange forming operation. This pre-tensioning prevents wrinkles and ply misalignment by ensuring the material is under tension when the high curvature bend is formed, eliminating the need to correct defects afterward.
Solution Approach 2:
The method applies a counteracting force in the form of tension to prevent the harmful effect of compression that would cause wrinkles during flange formation. By pre-applying this anti-action force, the material resists the compressive stresses that occur during the radial outward movement of the movable portion.
2Ease of manufacture
If a high curvature bend is used in the transition region, then the flange can be formed with a movable tool portion, but stress concentrations increase
Solution Approach 1:
The tension force is applied preliminarily to the transition region before flange formation to counteract the stress concentrations that will occur during high curvature bending. This pre-application of force ensures the material can withstand the stress without failing or deforming incorrectly.
3Device complexity
If the lay-up surfaces are substantially continuous, then the tool is simpler, but the low curvature transition region cannot be pre-defined
Solution Approach 1:
Instead of pre-defining the low curvature transition region on the tool's lay-up surface, the method preliminarily applies a tension force to the pre-form material in the transition region during forming. This force-induced approach allows the continuous lay-up surface to produce the desired low curvature transition without requiring complex tooling modifications.
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 method effectively reduces stress concentrations and improves structural characteristics by ensuring a low curvature transition and minimizing defects like wrinkling during the formation of composite components with integral flanges.
Implementation Method 1
the relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion, thereby causing a tension force in at least the flange region of the pre-form
Data Source
AI summary
There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.