Composite Ply Curving via Shear Angle Adjustment
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Solution Overview
Problem
The traditional method of positioning composite plies along an arcuate surface, such as airplane fuselages, faces challenges including discontinuity of reinforcing fibers, thickness build-up, labor intensiveness, and added weight due to the limitations of 0-degree plies in accommodating aggressive curvatures.
Innovation Solution
A method and device that involves placing a ply with longitudinal fiber tows along a curved edge, rotating the end portions to align the tows in a curved direction, and breaking bonds to allow sliding, thereby increasing the shearing angle and accommodating curvature without bulging, using a curving unit with a clamp and pivot axis to facilitate differential displacement of the tows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple overlapping 0-degree ply sections are disposed adjacent to one another to accommodate aggressive curvatures, then the curvature accommodation capability is improved, but the component weight increases and fiber continuity is lost
Solution Approach 1:
The invention changes the shearing angle parameter of the 0-degree ply from its original limited value to a larger value through mechanical shearing. This allows the ply to accommodate aggressive curvatures without requiring multiple overlapping sections, thereby reducing weight while maintaining fiber continuity and structural integrity
2Adaptability or versatility
If multiple overlapping 0-degree ply sections are disposed adjacent to one another to accommodate aggressive curvatures, then the curvature accommodation capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The invention transforms the ply's shearing angle parameter through mechanical shearing, enabling a single ply to achieve curvature accommodation that previously required multiple overlapping sections. This simplifies the manufacturing process by eliminating the need to position and bond multiple separate ply sections, reducing labor intensity and manufacturing complexity
3Adaptability or versatility
If multiple overlapping 0-degree ply sections are disposed adjacent to one another to accommodate aggressive curvatures, then the curvature accommodation capability is improved, but the thickness uniformity deteriorates
Solution Approach 1:
By mechanically shearing the 0-degree ply to increase its shearing angle, the invention enables the single ply to conform to aggressive curvatures without overlapping. This eliminates the thickness build-up that occurs with multiple overlapping plies, maintaining uniform thickness and improving manufacturing precision
4Adaptability or versatility
If the shearing angle of the ply is increased to accommodate aggressive curvatures, then the curvature accommodation capability is improved, but the fiber alignment deteriorates
Solution Approach 1:
The invention mechanically shears the ply to increase the shearing angle parameter, which enables curvature accommodation. The shearing process is designed to maintain fiber alignment within the ply structure, preserving the reinforcing effectiveness and structural strength while achieving the necessary adaptability for aggressive curvatures
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 allows a single sheet of 0-degree ply to conform to curved surfaces with increased shearing angle, reducing material wastage, labor, and weight, while maintaining structural strength, and enabling precise, repeatable curving of composite components.
Implementation Method 1
rotating at least one of the two end portions away from the arcuate surface about a pivot axis normal to the ply, so as to cause sliding of at least some of the plurality of fiber tows relative to each other
Data Source
AI summary
A method and device of positioning a ply of material for a composite component along an arcuate surface are presented. The ply comprises two end portions and a plurality of fiber tows extending longitudinally between the two end portions. The arcuate surface has a curved edge and a planar surface extending from the curved edge. The method comprises placing a first longitudinal edge portion of the ply along the curved edge; and rotating at least one of the two end portions away from the arcuate surface about a pivot axis normal to the ply, so as to cause sliding of at least some of the plurality of fiber tows relative to each other, and substantial aligning of the plurality of fiber tows in a curved direction along the arcuate surface. A method of positioning a ply of material for a composite component onto a curved mandrel is also presented.