Composite Preform Compaction Tool Wedge Mechanism
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Solution Overview
Problem
The manufacturing of complex composite products, such as stator vane rings for gas turbine engines, involves increased part count and complexity, leading to higher costs due to the individual laying up and consolidation of component parts.
Innovation Solution
A tool arrangement comprising a support tool, component moulds with wedge cavities, and wedges that compact component preforms without additional fastenings or dynamic force, utilizing differential thermal expansion for further compaction, allows for the formation of integral components from multiple parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual component parts are laid up and consolidated separately, then manufacturing flexibility is maintained, but part count and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple component preforms into a single integrated tool arrangement where all components are consolidated simultaneously in one moulding operation. The tool includes a support structure for multiple component preforms arranged in their final positions, with a single closure member that consolidates all components together, eliminating the need for separate laying up and consolidation steps for each component.
2Strength
If additional fastenings are used to attach tool parts together, then structural integrity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The tool arrangement employs self-service mechanisms where the closure member itself provides the structural connection without requiring additional fastenings. The closure member is designed to engage with the support structure through self-aligning features and inherent mechanical interlocking, making the tool self-assembling and eliminating the need for separate fastening operations.
3Manufacturing precision
If additional dynamic force is applied for preform compaction, then compaction quality is improved, but energy consumption and device complexity increase
Solution Approach 1:
The tool arrangement uses gravity as a beneficial force rather than overcoming it. The closure member is designed to apply compaction force by utilizing its own weight and the gravitational force on the preforms, eliminating the need for additional dynamic compaction forces. The geometry of the closure member and support structure works together to convert gravitational force into effective compaction pressure.
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 method simplifies the formation of integral components by eliminating the need for additional fastenings and dynamic force, reducing manufacturing complexity and costs while achieving effective compaction of composite preform assemblies.
Implementation Method 1
The wedges may comprise a first material and the enclosure may comprise a different second material, and the first material may have a higher coefficient of thermal expansion than the second material. When the tool is heated, the differing coefficient of thermal expansion results in differential thermal expansion between the wedges and the enclosure, which may further compact the preform.
Data Source
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AI summary
There is disclosed a tool arrangement for compacting a composite preform assembly comprising a support structure preform and an array of component preforms each extending from the support structure preform and spaced apart along the support structure preform. The tool arrangement comprises a support tool defining a lay-up surface for laying up the support structure preform; a plurality of component moulds, each component mould comprising a pair of blocks configured to cooperate with one another to receive and compact a respective component preform extending from the support structure therebetween, each block having a compaction surface for engaging the component preform and a driving surface, wherein the component moulds are arranged along the support tool so that a plurality of wedge cavities are defined between non-parallel driving surfaces of adjacent component moulds; and a plurality of wedges configured to be received in the wedge cavities and to cooperate with the respective driving surfaces of the component moulds to drive the adjacent blocks to compact respective component preforms.