Composite Hole Formation with Iris Diaphragm Support
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Solution Overview
Problem
The existing methods for creating holes in composite materials, such as fiber-reinforced plastics, often result in material weakening and waste generation, as they either drill or punch the material, leading to potential fatigue and crack formation, and are time-consuming and costly.
Innovation Solution
A method using an iris diaphragm piercing aid where a tip is pressed through the component, supported by an iris diaphragm that adapts its opening size to the tip, minimizing material loss and reinforcing the hole area, thus preventing significant fiber destruction and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drilling or punching is used to create holes in composite materials, then holes can be formed for fastener elements, but material is weakened and waste is generated
Solution Approach 1:
A support with an iris diaphragm is introduced as an intermediary device between the tip and the composite material. The iris diaphragm adapts its opening size to match the tip diameter, creating a controlled interface that prevents material escape and distributes pressure evenly, allowing hole formation without compromising material strength
Solution Approach 2:
The iris diaphragm dynamically changes its opening parameter during the hole formation process. The opening size is adjusted to match the tip diameter, transforming the support structure from a static to a dynamically adaptable configuration that optimizes the hole formation process while preserving material integrity
2Ease of manufacture
If drilling or punching is used to create holes, then holes are formed, but material residues or waste slugs are generated
Solution Approach 1:
The iris diaphragm acts as a mediator that confines the composite material during tip penetration. By adapting its opening to the tip diameter, it prevents material from escaping sideways, ensuring that material is displaced primarily in the axial direction rather than forming waste residues
Solution Approach 2:
Instead of removing material through drilling or punching, the invention inverts the approach by using compression and displacement. The tip presses the material through the adapted opening of the iris diaphragm, causing material to be pushed forward rather than cut or removed, thereby eliminating waste generation
3Productivity
If conventional drilling or punching methods are used, then holes can be created quickly, but the component is weakened in the hole region
Solution Approach 1:
The iris diaphragm changes its opening parameter dynamically during the process, adapting to the tip diameter. This parameter adjustment allows the system to maintain optimal pressure distribution throughout the hole formation process, preventing material weakening while preserving production efficiency
Solution Approach 2:
The support with iris diaphragm serves as a mediator that distributes the mechanical stress from the tip across a broader area of the composite material. This stress distribution prevents localized weakening that would occur with direct drilling or punching, while maintaining rapid hole formation capability
Data Source
AI summary
A method of manufacturing a hole in a component consisting of a composite material, such as a fiber or fabric reinforced plastic part, wherein the component, having first and second oppositely disposed sides, is placed with its first side on a support having an iris diaphragm. A tip which diverges in the axial direction is pressed from the second side of the component through the component, which optionally has a pre-piercing, for formation of the hole or for enlargement of the pre-piercing. The iris diaphragm has a smaller starting opening which receives a narrower region of the tip and opens into a larger opening with increasing penetration of the component by the tip, the component is supported during hole formation over an as large as possible area from the first side. A piercing aid in the form of an iris diaphragm or a die button is likewise claimed.