Composite Part Inspection Within Curing Mold
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Solution Overview
Problem
Composite parts, such as aircraft components, often deform during manufacturing due to structural changes during the curing process, requiring additional processing steps like fitting onto a trim tool for inspection, which is time-consuming and prone to errors, especially for large or complex parts.
Innovation Solution
A method and system where parts are formed in a mold with a modified design that compensates for deformation, allowing for finishing and inspection while still in the mold, using automated equipment to ensure conformance to the target design, eliminating the need for subsequent fitting onto a trim tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the part is removed from the mold for inspection and finishing, then the part can be inspected and finished, but additional time and resources are required and errors may be introduced
Solution Approach 1:
The mold is designed with a modified shape that anticipates and compensates for the deformation that will occur during curing. By performing the compensation action in advance (in the mold design phase), the part achieves its target dimensions without requiring subsequent correction steps, thereby reducing manufacturing cycle time while maintaining inspection accuracy
Solution Approach 2:
The inspection and finishing operations are merged into the mold cavity environment. The part is inspected and finished while still constrained within the mold, eliminating the need for separate handling and positioning steps that consume time and introduce errors
2Ease of manufacture
If the part is removed from the mold for finishing, then the part can be finished, but the process becomes more complex and error-prone
Solution Approach 1:
The finishing operations are merged with the molding process by maintaining the part within the mold cavity during finishing. This integration simplifies the overall manufacturing process by eliminating the need for transfer operations, repositioning, and handling between different equipment stations, thereby reducing process complexity while maintaining ease of manufacture
Solution Approach 2:
The mold itself serves as an intermediary structure that provides both the forming and finishing environment. By using the mold as the intermediate platform for both shaping and finishing operations, the process avoids the complexity of coordinating multiple separate devices and operation sequences
3Manufacturing precision
If the mold shape is modified to compensate for deformation, then the part conforms to target design after removal, but the mold design becomes more complex
Solution Approach 1:
The mold is designed with a deliberately modified shape that applies a counteracting deformation opposite to the expected curing shrinkage or distortion. This preliminary anti-action compensates for the anticipated dimensional changes, allowing the part to achieve its target dimensions after curing without requiring complex post-processing or adjustment mechanisms
Solution Approach 2:
The mold geometry parameters are intentionally altered from the target part dimensions to account for expected material behavior during curing. By changing the mold's dimensional parameters in advance, the system compensates for material shrinkage or expansion, achieving accurate final dimensions without adding mechanical complexity to the mold structure
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 approach reduces manufacturing time and errors by allowing for accurate inspection and finishing within the mold, ensuring parts conform to the original design without the need for additional handling, thus enhancing efficiency and reducing human or machine error.
Implementation Method 1
The part is cured in the mold by heating the part to a temperature of at least 200° C.
Implementation Method 2
the part may not retain its shape after being removed from the mold on which it is cured due to structural changes that occur in the part during the curing process
Data Source
AI summary
A manufacturing method is adapted for materials that are susceptible to deformation during the manufacturing process, such as composite parts that change shape during curing. The method includes modifying a part design to compensate for changes in the shape of the part that occur during a curing phase of the manufacturing process. A manufacturing mold is created according to the modified part design, then a part is formed in the mold and cured in the mold. While the part is still in the mold after the curing phase, the part is finished according to the modified part design wherein excess material is removed and apertures are created. While the part is still in the mold after the finishing phase, the finished part is inspected using automated inspection equipment to confirm that the finished part conforms to the modified part design.