Composite Tube Demolding by Sequential End Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in efficiently removing composite parts from mandrels without damaging either the part or the mandrel, particularly when the composite part fully encircles the mandrel, as existing methods like breakdown mandrels are costly, time-consuming, and prone to defects due to ill-fitting pieces or improper assembly.
Innovation Solution
A demolding tool with a controller and actuators that apply forces to deform the workpiece after cutting it along a longitudinal direction, allowing for partial disengagement from the mandrel, enabling the use of a unitary mandrel and minimizing the need for splice joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a breakdown mandrel is used to facilitate removal of composite parts, then the composite part can be removed without damage, but the mandrel becomes significantly more difficult and expensive to design and manufacture
Solution Approach 1:
The mandrel is divided into multiple separable segments or pieces that can be assembled to form the complete mandrel shape during composite material layup, then disassembled to allow removal of the cured composite part. This segmentation enables the mandrel to be taken apart without damaging either the mandrel itself or the composite part being removed.
Solution Approach 2:
The mandrel transitions from a static, fixed structure during composite fabrication to a dynamic, disassemblable structure during removal. The mandrel pieces can be moved and reconfigured - assembled for manufacturing and disassembled for demolding - providing adaptability that resolves the contradiction between maintaining structural integrity and enabling part removal.
2Reliability
If a breakdown mandrel is used, then composite parts can be removed, but fabrication time increases due to disassembly, cleaning, and reassembly for each use
Solution Approach 1:
The mandrel segments are pre-designed with standardized interfaces and connection mechanisms that enable quick assembly and disassembly. The preliminary design of these connection features allows the mandrel to be rapidly configured for each manufacturing cycle without requiring time-consuming custom fitting or complex alignment procedures.
3Reliability
If a breakdown mandrel is used, then composite parts can be removed, but defects may occur due to ill-fitting pieces or improper cleaning
Solution Approach 1:
The mandrel segments are pre-designed with tolerance compensation features and alignment mechanisms that cushion against fitting errors. These built-in compensations prevent ill-fitting pieces from causing defects in the composite part, ensuring that normal variations in manufacturing tolerances do not lead to quality problems during assembly and disassembly.
4Reliability
If the composite part is cut into pieces for removal, then the part can be separated from the mandrel, but additional weight is added due to splice joints
Solution Approach 1:
Instead of cutting the composite part into pieces for removal and then splicing them back together (which adds weight), the approach is inverted: the mandrel is cut or disassembled into pieces, allowing the composite part to be removed as a single intact piece. This eliminates the need for splice joints and the associated weight penalty while still enabling separation from the mandrel.
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 allows for efficient removal of composite parts from mandrels without disassembling the mandrel, reducing manufacturing costs and minimizing weight additions, while ensuring the integrity of both the mandrel and the composite part.
Implementation Method 1
cause the first plurality of actuators to apply, via the first plurality of couplers, first forces to the workpiece to deform the workpiece and at least partially disengage the first end of the workpiece from the first end of the mandrel
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.