Composite Panel Bending Tool with Curved Flange Slot
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Solution Overview
Problem
Current methods for creating bends in composite panels for aircraft are time-consuming and costly, requiring separate molds for each configuration and additional tools for angle or location changes, leading to complexity and increased costs.
Innovation Solution
A method and apparatus that form a bend in composite panels by identifying the location and angle, cutting a slot with a curved flange using a tool, and bending the panel without the need for additional tools, utilizing a slot forming tool capable of creating a slot with a curved flange in a single pass, allowing for flexible angle and radius adjustments without requiring new tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate molds are used for each composite panel configuration, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
A single bending tool with an adjustable bending radius guide is designed to create multiple bend configurations (different angles and radii) on composite panels. The guide can be repositioned along the panel edge, allowing one tool to perform the function of multiple specialized molds, thereby reducing tooling complexity while maintaining bend accuracy through controlled positioning.
Solution Approach 2:
The bending tool incorporates an adjustable guide that can be dynamically repositioned to different locations and angles on the panel. This dynamic adjustability allows the same tool to adapt to various bend requirements (different radii and angles) without requiring multiple fixed molds, resolving the contradiction between precision and complexity.
2Manufacturing precision
If new molds are created for angle or location changes, then manufacturing precision is improved, but loss of time and productivity decrease
Solution Approach 1:
The bending tool features a dynamically adjustable guide that can be repositioned to different locations and angles on the panel. This eliminates the need to create and swap physical molds for different bend configurations, allowing rapid adjustment while maintaining precision through controlled positioning of the adjustable guide.
Solution Approach 2:
The tool allows change of bending parameters (radius and angle) by adjusting the position of the guide along the panel edge rather than changing the tool itself. This parameter adjustment capability enables different bend configurations to be achieved with the same tool, eliminating mold change time while maintaining configuration accuracy.
3Manufacturing precision
If multiple molds are used for different bend configurations, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
A single bending tool with an adjustable guide serves multiple bend configuration functions that would otherwise require separate specialized molds. This universal tool reduces the total number of tools needed, lowering manufacturing cost while maintaining bend angle accuracy through precise positioning and control of the adjustable guide.
Data Source
AI summary
An apparatus for forming a bend in a composite panel is provided. An angle and a radius bend are identified for a bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2π*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA−2K(R−T), wherein K is Tan(A/2) and T is a thickness of the composite panel.