Composite Ring Frame Hot-Forming Process
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Solution Overview
Problem
The existing manufacturing processes for aeronautical ring frames, primarily using metal structures, result in long assembly times and excessive weight due to the need for multiple components and riveting, which can be optimized by integrating composite materials.
Innovation Solution
The process involves hot-forming C- and L-shaped preforms using specific tools and techniques, including pressure and temperature cycles, to create integrated composite ring frames suitable for resin transfer moulding (RTM), allowing for localized adhesion and precise deformation without the use of an autoclave, enabling complex geometries and improved dimensional precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal structures with multiple components and riveting are used, then structural strength is achieved, but assembly time increases and weight increases
Solution Approach 1:
The patent merges multiple separate metal components (Z-section and angle sections) into a single integrated composite ring frame structure. The composite preform is manufactured as one unified piece using RTM technology, eliminating the need for riveting multiple components together, thus reducing assembly time while maintaining structural strength.
Solution Approach 2:
The patent uses composite materials (carbon fiber reinforced polymer) instead of traditional metal structures. The composite preform is impregnated with resin and cured to form a strong, lightweight integrated structure that replaces multiple riveted metal components, achieving both strength and reduced assembly time.
2Strength
If metal structures with multiple components are used, then structural strength is achieved, but weight increases
Solution Approach 1:
The patent employs composite materials (carbon fiber reinforced polymer) to manufacture the integrated ring frame structure. These composite materials provide high strength-to-weight ratio, achieving the required structural strength while significantly reducing the overall weight compared to traditional riveted metal structures.
Solution Approach 2:
By integrating multiple components into a single composite structure, the patent eliminates the weight of fasteners (rivets) and reduces the total material required. The unified composite preform structure achieves the same structural strength with less weight than assembled metal components.
3Ease of manufacture
If shaped sheet metal sections are manufactured in two separate pieces and riveted, then manufacturing feasibility is maintained, but assembly complexity increases
Solution Approach 1:
The patent merges the manufacturing process into a single integrated RTM operation where the entire ring frame structure is formed in one piece from a single composite preform. This eliminates the need to manufacture separate Z-sections and angle sections and rivet them together, thereby reducing assembly complexity while maintaining manufacturing feasibility through established composite manufacturing techniques.
4Strength
If integrated composite structures are manufactured using traditional autoclave methods, then structural quality is achieved, but surface finish precision is reduced
Solution Approach 1:
The patent introduces a specialized tooling system with a hold-down plate and pneumatic actuator as an intermediary between the autoclave and the composite preform. This tooling system applies controlled pressure and maintains precise positioning during curing, enabling the manufacturing of integrated composite structures with high surface finish precision (tolerances ≤0.2 mm) while maintaining structural quality.
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 reduces assembly time, achieves high dimensional precision, and results in lighter, more integrated structures with improved thickness control, facilitating the production of ring frames with complex geometries while maintaining precise radii and reducing manufacturing duration.
Implementation Method 1
Hot-forming planar rectangular laminates by placing layers of pieces of material on a first tool in predetermined positions and number and applying pressure and temperature so that the pieces of material adhere to one another only locally
Implementation Method 2
applying pressure and temperature so that the pieces of material adhere to one another only locally
Implementation Method 3
placing an elastic membrane on the tool and applying a temperature and vacuum cycle
Implementation Method 4
applying a temperature and vacuum cycle
Implementation Method 5
Hot-forming the preforms into a C and L shape on a second curved tool by deforming said laminates of right angle section thereon
Implementation Method 6
applying a temperature and vacuum cycle
Data Source
AI summary
The present invention relates to a process for manufacturing composite ring frames for aeronautical fuselages by means of the application of the RTM technology to two preforms with C- and L-shaped sections manufactured using two tools (21, 55) in the following steps: providing the material; hot-forming planar rectangular laminates (41); hot-forming laminates of right angle section (51) on one part of right angle section of the first tool (21), placing an elastic membrane (55) and applying a temperature and vacuum cycle; hot-forming the preforms into a C shape (11) and L shape (13) on a second curved tool (55) by deforming said laminates of right angle section (51) thereon, and applying a temperature and vacuum cycle. The invention also relates to said tools (21, 55).