Composite Flange Forming via Pre-form Segmentation and Tension
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Solution Overview
Problem
Manufacturing composite components with integral flanges using composite materials like Carbon Fibre Reinforced Polymer (CFRP) often faces challenges in achieving a low curvature transition between the main body and the flange, leading to stress concentrations and forming defects such as out-of-plane wrinkles and ply misalignment.
Innovation Solution
A method involving a tool with a main body portion and a flange-forming portion, where the pre-form has contiguous regions with varying thickness and layer counts, allowing relative movement to create a tension force during flange formation, thereby producing a composite component with a low curvature transition region.
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 the transition region between the main body and flange has high curvature leading to stress concentrations and forming defects
Solution Approach 1:
The pre-form is divided into three distinct regions: a first region corresponding to the main body, a second region corresponding to the flange, and a third region with reduced thickness. This segmentation allows each region to be optimized independently - the third region acts as a transition zone that enables low curvature formation while the second region forms the final flange geometry.
Solution Approach 2:
The third region of the pre-form is given different local quality (reduced thickness) compared to the second region. This local variation in material distribution creates a tension force during forming that enables the second region to form with low curvature, reducing stress concentrations and preventing forming defects in the transition zone.
2Manufacturing precision
If fibre reinforcement material is applied to form a pre-form with varying thickness regions, then low curvature transition can be achieved, but the device complexity increases
Solution Approach 1:
The thickness parameter of the pre-form is varied across different regions. The third region has reduced thickness compared to the second region, creating a gradient that generates the necessary tension force during forming. This parameter change enables low curvature transition formation without requiring complex tooling or multiple forming operations.
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 ensures improved structural characteristics and reduced stress concentrations by achieving a low curvature transition between the main body and flange, minimizing defects like wrinkles and misalignment, while also allowing for material reduction and efficient material use.
Implementation Method 1
the relative movement of the flange-forming portion and the main body portion causes sliding movement between the second and third regions of the pre-form and the flange-forming, thereby producing a tension force in at least the second region of the pre-form during forming of the flange
Data Source
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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 having first, second and third contiguous regions, the first region corresponding to the main body of the component and the second region corresponding to the integral flange of the component; and causing relative movement between the flange-forming portion and the main body portion so that the second region of the pre-form deforms to form the flange; wherein the relative movement of the flange-forming portion and the main body portion causes sliding movement between the second and third regions of the pre-form and the flange-forming, thereby producing a tension force in at least the second region of the pre-form during forming of the flange.