Composite Part Manufacturing with Segmented Heating
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Solution Overview
Problem
Traditional ATL technology for manufacturing composite material parts with large thickness and complex geometries faces issues such as wrinkle formation and uneven heating, which fail to meet quality standards for aircraft parts due to inextensibility of carbon fibers and inefficient heat distribution.
Innovation Solution
The method involves laminating prepreg material strips on a tool with a male surface and detachable parts forming an angle, allowing for easier bending and reduced risk of wrinkles, with the detachable parts being removed during forming to create a continuous surface for uniform heat application and reduced temperature exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ATL technology is used for laminating flat parts with traditional heating methods, then the manufacturing process is simple, but wrinkle formation occurs in bending areas and overheating occurs in layers closest to the heat source
Solution Approach 1:
The heating system is segmented into multiple independent heating zones (first heating zone and second heating zone) that can be controlled separately. This allows different temperature profiles to be applied to different regions of the workpiece, preventing both wrinkle formation in bending areas and overheating in layers closest to the heat source while maintaining manufacturing simplicity
Solution Approach 2:
Different heating intensities are applied to different local regions of the workpiece. The first heating zone provides lower temperature for bending areas to prevent wrinkles, while the second heating zone provides higher temperature for non-bending areas to ensure proper curing, thus achieving local quality optimization
2Ease of manufacture
If heat is supplied from the top part of the forming machine, then the heating process is simple, but layers closest to the male tool experience very high temperatures causing material degradation
Solution Approach 1:
The heating system is divided into multiple independent heating zones with different temperature controls. The second heating zone is specifically designed to provide lower temperature heating for areas close to the male tool, preventing material degradation while the first heating zone maintains higher temperature for effective curing in other areas
Solution Approach 2:
The temperature parameter is changed and optimized for different regions. By controlling the temperature in the second heating zone to be lower than in the first heating zone, the patent prevents overheating and material degradation in layers closest to the male tool while ensuring adequate curing temperature in other areas
3Shape
If carbon fiber layers are bent at approximately 90° in parts of big thickness, then the desired complex geometry is achieved, but sliding between layers occurs causing wrinkle formation
Solution Approach 1:
The prepreg material is pre-heated in the first heating zone before bending to increase its flexibility and reduce interlayer sliding. This preliminary heating action allows the material to be bent at large angles (approximately 90°) without causing wrinkle formation, thus achieving complex geometry while maintaining surface quality
Solution Approach 2:
The temperature parameter is used to change the physical state of the prepreg material before bending. By heating the material to an appropriate temperature range, its viscosity and flexibility are modified, allowing smooth bending at 90° angles without layer sliding and wrinkle formation
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 minimizes wrinkle formation and reduces material degradation by allowing for more controlled bending and heat distribution, ensuring parts meet aeronautical industry quality standards.
Implementation Method 1
The heat in the forming step is applied by means well known in the state of the art, which are embedded in the upper part of the forming machine
Implementation Method 2
application of vacuum at low speed to pressure-bend the laminate against the male tool
Implementation Method 3
curing the part obtained in the previous step, in an autoclave in which high pressure and temperature are applied
Data Source
AI summary
The manufacturing method object of the invention comprises the following stages: A) stacking strips of prepreg material on a laminating tool (14), so that an angled laminated part (2) is obtained comprising a central section (2a) contained in a first plane (12), at least one side section (2b) contained in a second plane (13), and at least one bending axis (5) between the central section (2a) and the at least one side section (2b), so that, the first plane and the second plane form an angle α; B) forming of the angled laminated part (2) comprising bending along the bending axis (5) the, at least, one side section with respect to the central section (2a), obtaining a formed part (6); C) curing, of the formed part (6).