Composite Component Forming Tool with Reference Apertures
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Solution Overview
Problem
Manufacturing operations on composite components, especially asymmetric ones, are time and labor intensive due to warping and distortion, making precise operations like drilling holes challenging and costly.
Innovation Solution
A forming tool with reference apertures is used to form and cure composite components, allowing for precise manufacturing operations like drilling attachment apertures before the component is removed, ensuring accuracy and reducing time and expense.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If composite components are formed and cured using conventional methods, then the components achieve desired strength and shape, but the components warp and distort during handling making subsequent manufacturing operations difficult and time-consuming
Solution Approach 1:
The patent applies preliminary action by performing manufacturing operations (drilling, countersinking, fastener installation) on the composite component while it is still secured to the forming tool immediately after curing, before the component is removed and subjected to warping and distortion. This timing ensures that all precision work is completed when the component is in its most stable and accurately positioned state.
Solution Approach 2:
The patent merges the forming tool with the manufacturing operation fixture by designing the forming tool to include integrated positioning features, reference apertures, and securing mechanisms that allow manufacturing operations to be performed directly on the tool without removing the component. This consolidation eliminates the need for separate handling and repositioning steps.
2Ease of operation
If asymmetric composite components are handled after curing, then the components can be removed from the forming tool, but the asymmetric components warp and distort from their desired positions
Solution Approach 1:
The patent performs all necessary manufacturing operations while the component is still secured to the forming tool, completing all work before the component is handled and removed. This preliminary completion of operations eliminates the risk of warping affecting subsequent handling and assembly operations.
Solution Approach 2:
The forming tool serves as an intermediary that maintains the component's shape and position during the transition from curing to manufacturing operations. The tool acts as a stable reference frame that prevents warping and distortion during the critical period when the component is most vulnerable to shape changes.
3Productivity
If manufacturing operations are performed on composite components after removal from the forming tool, then the components can be freely handled, but the operations become time and labor intensive due to warping and distortion
Solution Approach 1:
The patent combines the forming and manufacturing operation stages into a single integrated process by performing all manufacturing operations while the component is still secured to the forming tool. This merging eliminates the need for separate handling, positioning, and securing steps that would otherwise be required after component removal.
Solution Approach 2:
The patent performs all manufacturing operations in advance, while the component is still in its most stable and accurately positioned state on the forming tool. This preliminary completion of operations maximizes productivity by eliminating subsequent repositioning and correction work.
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 method improves the accuracy and reduces the time and expense of manufacturing operations by allowing precise operations on cured composite components while they are still securely held by the forming tool, minimizing distortion and enhancing their suitability for assembly.
Implementation Method 1
providing a forming tool having a base portion and at least one retaining portion; forming an uncured composite component on the forming tool
Implementation Method 2
curing the composite component
Data Source
AI summary
Methods and systems for manufacturing composite components, including asymmetric composite components, are disclosed. In one embodiment, a method of forming a composite component includes providing a forming tool having a base portion and at least one retaining portion; forming an uncured composite component on the forming tool; curing the composite component; performing a manufacturing operation on the cured composite component engaged with the forming tool; and after performing the manufacturing operation on the cured composite component, removing the cured composite component from the forming tool. In further embodiments, the forming tool may have a plurality of reference apertures disposed therethrough for performing drilling operations on the cured composite component.