Composite Parts Production with Support Material Void Filling
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Solution Overview
Problem
Current methods for manufacturing composite parts with complex cross-sections in the aeronautical field are limited, as they either require multiple mandrels or cannot produce parts with overhanging zones, restricting the production of parts with variable geometries and significant mass reduction.
Innovation Solution
An automatic process involving layer-by-layer manufacturing using a combination of filament winding, CAD-driven layer construction, and the use of support materials to maintain the part during production, allowing for the creation of composite parts with complex cross-sections and overhanging zones from a single tool, utilizing a resin matrix and reinforcement materials like carbon or glass fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If filament winding is used to manufacture composite parts, then continuous deposition of yarns is achieved, but only parts of revolution with simple geometries can be produced
Solution Approach 1:
The manufacturing process is segmented into multiple winding phases, each corresponding to a specific geometric zone of the part. The mandrel is divided into sections with different winding parameters, allowing complex cross-sections to be built layer by layer while maintaining continuous deposition productivity.
Solution Approach 2:
The winding process employs dynamic adjustment of deposition parameters during rotation. The system can change yarn deposition rate, layer thickness, and winding angle in real-time based on the mandrel's rotational position, enabling complex geometries to be formed continuously.
2Adaptability or versatility
If a fabric is wound around a mandrel to produce complex cross-section parts, then complex geometries are achieved, but one mandrel per geometry is required
Solution Approach 1:
A single universal mandrel design is used for all part geometries. The mandrel incorporates adjustable winding guides and deposition zones that can be reconfigured through software control, eliminating the need for multiple specialized mandrels while maintaining the ability to produce various complex cross-sections.
Solution Approach 2:
The mandrel system uses variable winding parameters (speed, tension, deposition rate, layer angle) that can be changed during operation. This allows the same physical mandrel to produce different complex geometries by adjusting process parameters rather than changing the mandrel structure.
3Ease of manufacture
If traditional molding processes are used, then parts are produced, but significant mass reduction is not achieved
Solution Approach 1:
The process uses composite materials combining fibers (carbon, glass, aramid) with polymer matrices to create parts that are both lightweight and structurally sound. The layer-by-layer construction allows optimization of fiber orientation and material distribution to achieve maximum strength-to-weight ratio.
Solution Approach 2:
Different regions of the part are constructed with different material compositions and fiber orientations based on local structural requirements. This allows mass reduction in non-critical areas while maintaining necessary strength and stiffness in load-bearing zones, optimizing the overall weight-performance balance.
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
Enables the production of composite parts with improved mechanical and thermal characteristics, allowing for direct assembly in applications like aircraft engines, with significant mass reduction and flexibility in producing complex geometries, while maintaining dimensional and mechanical requirements.
Implementation Method 1
the reinforcement is impregnated with a liquid resin by passing it through a bath (2)
Implementation Method 2
The impregnated or pre-impregnated reinforcement (22) is completely or partially polymerized to obtain a composite material (20)
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~3D
AI summary
The present invention relates to an automated layer-by-layer manufacturing process for a composite part of revolution with a complex cross-section, characterized in that it comprises the following steps: a) A coil (1) or roll comprising a reinforcement is continuously unwound; b) Optionally, the reinforcement is impregnated with a liquid resin by passing it through a bath (2); c) The impregnated reinforcement is wound onto a rotating cylindrical mandrel (4); d) The impregnated reinforcement is completely or partially polymerized to obtain a composite material; e) A support (21) and/or a support material is deposited on either side of the composite material constituting the part being manufactured so as to fill voids surrounding said part.