Composite Layup Tool via Friction Plug Welding

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Solution Overview

Problem

Existing methods for manufacturing composite part tools are costly, time-consuming, and result in heavy, thermally massive tools that require skilled labor and significant material waste, leading to long lead times and difficulties in movement and thermal management.

Innovation Solution

A method involving a lightweight base with a thin, incrementally formed metal sheet tool surface, where both the base and metal sheet are shaped using a numerically controlled machine tool, and the metal sheet is attached via friction plug welding to create a lightweight, efficient tooling system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid blocks of metal are machined to make tools, then durable metal tool surfaces are achieved, but material waste and machining time increase

Engineering Contradiction:

Improvetool surface durabilityVSAvoidmaterial waste

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The tool is segmented into two functional parts: a lightweight base structure and a thin metal sheet tool surface. The metal sheet is formed to match the desired tool shape and then attached to the base, separating the structural support function from the tool surface function. This eliminates the need to machine entire solid blocks, reducing material waste significantly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A thin metal sheet is used instead of thick solid metal blocks to create the tool surface. The thin sheet is formed to the desired shape and attached to the base structure, providing the necessary tool surface durability while minimizing material consumption and reducing overall tool weight.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If solid blocks of metal are machined to make tools, then durable tool surfaces are achieved, but machining time and lead times increase

Engineering Contradiction:

Improvetool surface durabilityVSAvoidmachining time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The tool manufacturing process is segmented into forming the metal sheet to shape and then attaching it to the base. This avoids the time-consuming process of machining solid blocks, significantly reducing lead times while still achieving durable tool surfaces through the formed metal sheet.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal sheet is formed to the desired tool shape in advance through incremental forming processes before being attached to the base. This preliminary shaping action eliminates the need for subsequent time-consuming machining operations to achieve the final tool geometry.

Inventive Principle:

Principle #10Preliminary action

3Strength

If thick solid plates are used to make tools, then structural strength is achieved, but tool weight increases

Engineering Contradiction:

Improvetool structural strengthVSAvoidtool weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The tool structure is segmented into a lightweight base that provides structural support and a thin metal sheet that provides the tool surface. This segmentation allows the base to be optimized for strength-to-weight ratio while the thin sheet minimizes weight, achieving both structural strength and reduced tool weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tool is constructed as a composite structure combining a lightweight base material with a thin metal sheet layer. This composite approach leverages the strengths of different materials to achieve structural integrity while minimizing overall weight, making the tool easier to move and handle.

Inventive Principle:

Principle #40Composite materials

4Stability of the object's composition

If tools with high thermal mass are used, then thermal stability is achieved, but heat-up and cool-down times increase

Engineering Contradiction:

Improvethermal stabilityVSAvoidheat-up and cool-down time

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of moving object

Solution Approach 1:

A thin metal sheet is used as the tool surface instead of thick solid metal, which inherently reduces thermal mass. The thin sheet provides sufficient thermal stability for the tool function while enabling faster heat-up and cool-down cycles, improving production efficiency.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The tool is segmented into a lightweight base and thin metal sheet, creating a structure with reduced overall thermal mass compared to solid block tools. This segmentation allows the tool to reach thermal equilibrium faster while maintaining adequate thermal stability during operation.

Inventive Principle:

Principle #1Segmentation

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 material costs, lead times, and tool weight, enabling faster and more cost-effective production of composite part tools with improved thermal management and ease of handling.

Implementation Method 1

The attachment process may be carried out by friction plug welding the formed metal sheet to a shaped surface on the base

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Data Source

PatentUS8316687B2Method for making a tool used to manufacture composite parts

Publication Date: 2012.11.27 THE BOEING CO

AI summary

A method is provided for making a composite part layup tool. A surface of a base is shaped and used as a tool to incrementally form a metal sheet. The formed metal sheet is friction plug welded to the shaped surface on the base to form a metal tool surface of the layup tool.