Composite Structure Manufacturing Using Roller Deformation
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Solution Overview
Problem
Existing methods for manufacturing composite structures for aircraft, such as those described in PTL 1, PTL 2, and PTL 3, face challenges including high costs due to the need for multiple mandrels for different structures, generation of ripples or wrinkles that reduce strength, and increased manufacturing time.
Innovation Solution
A composite structure manufacturing method and device that involves forming a laminate by laminating fiber reinforcing resin sheets, followed by a pressing deformation step using a rotating body to create recessed or projecting portions, and subsequent lateral and longitudinal deformation steps to achieve the desired shape, thereby suppressing the generation of ripples or wrinkles and reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple mandrels are prepared for different structures, then various composite structures can be manufactured, but the cost increases
Solution Approach 1:
The patent applies universality by designing a single mandrel that can manufacture multiple different composite structures. The mandrel includes a base body and a detachable pressing member that can be configured in various positions and orientations. By selectively arranging the pressing member, the same mandrel can produce different cross-sectional shapes and curvature radii, eliminating the need for multiple dedicated mandrels for different structures.
2Shape
If the laminate is curved or bent after cross-sectional shaping, then the desired longitudinal shape is achieved, but ripples or wrinkles are generated reducing strength
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses and projections in the laminate while it is still flat, before any curvature is applied. The pressing member presses specific regions of the flat laminate to create the cross-sectional shape in advance. This preliminary shaping ensures that when the laminate is subsequently curved or bent, the material is already configured to accommodate the deformation without generating ripples or wrinkles, thereby maintaining structural strength.
3Shape
If fiber reinforcing resin sheets are deformed one by one and then laminated, then the desired shape is achieved, but the manufacturing time increases
Solution Approach 1:
The patent applies merging by combining the deformation and lamination processes into a single integrated operation. Instead of deforming individual fiber reinforcing resin sheets separately and then laminating them, the pressing member simultaneously presses and deforms the entire laminate stack in one action. This unified approach achieves the desired cross-sectional shape while significantly reducing manufacturing time compared to sequential processing.
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
The proposed method effectively suppresses the generation of ripples or wrinkles, improves the strength of the composite structure, and reduces manufacturing time and cost by allowing for the use of a single device to form complex shapes without the need for multiple mandrels.
Implementation Method 1
a pressing deformation step of forming a recessed portion or a projecting portion in a predetermined portion of the laminate by pressing a plate surface of the laminate with a rotating body that rolls along the plate surface of the laminate
Data Source
AI summary
A composite structure manufacturing method comprising: a lamination step in which a plurality of fiber-reinforced resin sheets are laminated to form a plate-shaped laminate; a pressing deformation step in which a third roller or similar, which rolls along a plate surface of the laminate, is used to press the plate surface of the laminate, thereby forming a recessed section or a protruding section in a prescribed section of the laminate; a short direction deformation step in which, after the pressing deformation step, the laminate is deformed in the short direction to make the long direction cross-section into a prescribed shape; and a long direction deformation step in which, after the pressing deformation step, the laminate is deformed in the long direction to make the short direction cross-section into a prescribed shape.