Composite Flange Forming via Vacuum Diaphragm Deformation
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Solution Overview
Problem
Achieving uniform quality in the formation of outward facing flanges for aircraft engine case structures made from laminated composite materials is challenging due to the tendency of fibrous composite materials to disorganize under local or discontinuous forces, leading to issues like wrinkles, folds, fiber waviness, and buckling.
Innovation Solution
A method and apparatus involving a laminate component supported by a drum, a diaphragm member, and a forming tool that selectively engages the laminate component to deform it uniformly, maintaining the desired fiber architecture and avoiding flaws through controlled displacement and vacuum-assisted deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If local or discontinuous force is applied to form a flange, then flange formation is achieved, but the fibrous composite materials disorganize themselves causing wrinkles, folds, fiber waviness, and buckling
Solution Approach 1:
The patent changes the parameter of force distribution from local/discontinuous to uniform/continuous by applying vacuum pressure across the entire flange surface. This transforms the forming mechanism into a uniform compression process that maintains fiber architecture while achieving flange formation.
Solution Approach 2:
The patent employs vacuum pressure (pneumatics) to apply uniform force distribution across the flange surface. The vacuum system creates a continuous pressure field that deforms the composite material uniformly without causing local stress concentrations that would lead to fiber disorganization.
2Manufacturing precision
If uniform force is applied to maintain fiber architecture, then fiber architecture is preserved, but flange formation becomes difficult
Solution Approach 1:
The patent uses vacuum pressure to achieve uniform force distribution that facilitates flange formation while preserving fiber architecture. The pneumatic system provides continuous pressure that guides the material flow uniformly across the flange surface.
Solution Approach 2:
The patent changes the physical state and pressure distribution parameters to enable uniform deformation. By controlling vacuum pressure levels and application timing, the process achieves both flange formation and fiber architecture preservation simultaneously.
3Productivity
If traditional forming methods are used, then flange formation is achieved, but quality uniformity across the entire flange is difficult to achieve
Solution Approach 1:
The patent employs vacuum pressure distribution to achieve uniform quality across the entire flange surface. The pneumatic system ensures consistent force application from the center to the edges, eliminating the quality variations inherent in traditional mechanical forming methods.
Solution Approach 2:
The patent transforms the forming process by changing pressure distribution parameters from localized to uniform. This parameter change enables simultaneous achievement of high productivity and consistent quality across the entire flange surface.
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
The solution enables the formation of flanges with substantially uniform thickness and fiber architecture, free from wrinkles, folds, fiber waviness, and buckling, thereby improving the quality and consistency of composite engine case components.
Implementation Method 1
a diaphragm member extends between the drum and the laminate component... Movement of the diaphragm member deforms the laminate component away from the drum about an edge of the forming tool
Implementation Method 2
a vacuum is provided in fluid communication with the sealed forming chamber, the vacuum configured to selectively reduce the pressure in the chamber
Data Source
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AI summary
An apparatus for forming a flange has a laminate component and a drum supporting the laminate component. A forming tool selectively engages the laminate component. A diaphragm member extends between the drum and the laminate component and selectively engages the forming tool. Movement of the diaphragm member deforms the laminate component away from the drum about an edge of the forming tool, and the laminate component maintains a substantially uniform thickness.