Composite Workpiece Holding for As-Built Shape Conformance
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Solution Overview
Problem
Composite parts, especially large ones, tend to deform after being removed from their curing tools, leading to accuracy issues in machining operations and requiring post-machining adjustments, which complicates assembly and manufacturing processes.
Innovation Solution
A system and method for handling composite workpieces using a workpiece holder with a clamp and support members that index and conform the workpiece to its as-built shape, ensuring accurate machining and assembly by maintaining the workpiece in its reinforced shape post-curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If composite parts are removed from curing tools, then they can be processed further, but they deform and lose shape accuracy
Solution Approach 1:
The patent applies preliminary action by pre-forming the composite part on a curing tool that imparts the desired as-built shape, then using a workpiece holder to maintain that shape during subsequent processing. The holder is configured to conform to the as-built shape features, preventing deformation before machining operations occur.
Solution Approach 2:
The workpiece holder serves as an intermediary between the curing tool and the machining operations. It maintains the as-built shape features by providing support at specific conformance features, acting as a mediator that preserves geometric integrity during handling and processing.
2Manufacturing precision
If post-machining operations like shimming and additional drilling are performed, then machining accuracy is improved, but process complexity and time increase
Solution Approach 1:
The patent performs preliminary shaping by maintaining the as-built shape during machining through the workpiece holder. This preliminary action ensures that the part geometry remains stable and accurate throughout processing, eliminating the need for subsequent corrective operations like shimming or additional drilling.
Solution Approach 2:
The patent extracts and eliminates the need for post-machining corrective operations by preventing deformation in the first place. The workpiece holder design removes the requirement for shimming and additional drilling by maintaining geometric integrity throughout the machining process.
3Manufacturing precision
If post-machining adjustments are made, then shape accuracy is improved, but manufacturing time and cost increase
Solution Approach 1:
The workpiece holder is designed with conformance features that preliminarily establish and maintain the as-built shape before machining begins. This preliminary action ensures accuracy is achieved during the primary machining operations rather than requiring time-consuming post-machining adjustments.
4Manufacturing precision
If composite parts are held in a fixed position during machining, then machining accuracy is improved, but the parts may deform under clamping forces
Solution Approach 1:
The workpiece holder applies clamping forces at specific localized conformance features rather than distributing force across the entire part. This local quality approach provides stable positioning at critical locations while avoiding excessive stress on the composite structure that could cause deformation or damage.
Solution Approach 2:
The holder is designed to preliminarily establish the correct position and orientation using conformance features that match the as-built shape. This preliminary positioning ensures the part is correctly located before machining begins, maintaining both accuracy and structural integrity throughout the process.
Data Source
AI summary
A system for handling a composite workpiece includes a work cell and a plurality of workpiece holders to hold a composite workpiece in the work cell. Each one of the plurality of workpiece holders is selectively controlled to index the composite workpiece in the work cell and to conform the composite workpiece to an as-built shape of the composite workpiece.