Composite Laminate Ramp Manufacturing via Ply Segmentation
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Solution Overview
Problem
Conventional manufacturing methods for slim composite parts with double opposite stacking ramps face challenges, particularly with automatic laying technology at 90º and 45º directions, where upper plies are often too narrow, necessitating oversized ramps or double cutting to maintain uniform dimensions.
Innovation Solution
The method involves alternating groups of plies, where each successive ply is cut only once and laid in a staggered manner, with ends stepped successively to form rising and falling ramps, eliminating the need for oversized plies and reducing scrap material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional double cutting method is used to manufacture both rising and falling ramps, then both ramps can be manufactured with uniform ply dimensions, but the number of cuts per ply increases and scrap material is generated
Solution Approach 1:
The plies are divided into two groups: first plies that form the rising ramp and second plies that form the falling ramp. Each group is cut and positioned independently, allowing the rising and falling ramps to be manufactured separately rather than requiring double cutting of each ply. This segmentation reduces the number of cuts and minimizes scrap material while maintaining precise ramp dimensions.
Solution Approach 2:
Instead of cutting both ends of each ply to create both ramps (conventional approach), the invention inverts the approach by cutting only one end of plies in each group. The first plies are cut to form the rising ramp, and the second plies are cut to form the falling ramp, eliminating the need for double cutting and reducing waste.
2Manufacturing precision
If plies are cut at both ends to form both rising and falling ramps, then uniform ply dimensions can be maintained, but automatic laying technology becomes difficult to apply at 90o and 45o directions
Solution Approach 1:
The plies are segmented into two distinct groups with different cutting patterns. First plies are cut only at one end to form the rising ramp, while second plies are cut only at one end to form the falling ramp. This segmentation creates simpler, more uniform ply configurations that are easier to handle and apply using automatic laying technology at various orientations including 90o and 45o directions.
Solution Approach 2:
Different cutting patterns are applied to different groups of plies based on their specific function. First plies receive cuts optimized for the rising ramp, while second plies receive cuts optimized for the falling ramp. This local differentiation allows each ply group to have the optimal geometry for its specific ramp, improving both manufacturability and automatic laying applicability.
3Ease of manufacture
If oversized ramps are used to accommodate narrow upper plies, then automatic laying technology can be applied, but the ramp dimensions exceed the actual structural requirements
Solution Approach 1:
The cutting pattern is locally optimized for each ply group based on its position and function in the laminate. First plies are cut to precise dimensions for the rising ramp, and second plies are cut to precise dimensions for the falling ramp. This local optimization ensures that each ply has the exact dimensions needed for its specific ramp, eliminating the need for oversized ramps while maintaining compatibility with automatic laying technology.
Data Source
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AI summary
Composite structure, comprising a laminate (1) that comprises a set of plies (11, 12, 13, ...), the laminate (1) extending between a first edge (2) and a second edge (3) and comprising: - a rising ramp (4) and a falling ramp (5), the rising ramp (4) comprising a starting point (41) and an upper point (42) and the falling ramp (5) comprising the upper point (42) and an end point (51), - plies (11, 12, 13, 14, 15, 16, ...) partially located over their preceding ply (12, 13, 14, 15, ...) and that alternatively extend from the first edge (2) or the second edge (3) and are shorter than the ply located before the preceding ply so that their ends (43, 44, 52, 53, ...) are stepped successively until they reach the top of the ramp (3, 4).