Composite Tube Demolding on a Unitary Tapered Mandrel
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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 such as 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 applies 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 disassembly, while allowing for a single splice joint to join the cut edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a breakdown mandrel is used to facilitate removal of composite part, then the composite part can be removed without damage, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The mandrel is divided into multiple separable segments or sections that can be detached from each other. This allows the composite part to be removed by separating the mandrel segments rather than breaking down the entire structure, reducing complexity while maintaining damage-free removal capability
Solution Approach 2:
The mandrel incorporates movable or adjustable components that allow it to change configuration during the demolding process. This dynamic capability enables the mandrel to adapt to the removal process without requiring a completely complex breakdown structure
2Reliability
If a breakdown mandrel is used, then the composite part can be removed, but the fabrication time increases due to disassembly, cleaning, and reassembly
Solution Approach 1:
The mandrel is pre-configured with separation features or release mechanisms that are prepared in advance. This preliminary preparation allows for quick and easy disassembly during demolding without requiring time-consuming manual breakdown procedures
Solution Approach 2:
The mandrel uses movable components that can be quickly repositioned or detached, reducing the time required for disassembly and reassembly cycles compared to fixed breakdown mandrel structures
3Manufacturing precision
If ill-fitting pieces or improper assembly of breakdown mandrel are used, then defects occur in the composite part, but using a unitary mandrel increases the difficulty of part removal
Solution Approach 1:
The mandrel is segmented into sections with standardized interfaces that ensure proper fit and alignment. This segmentation maintains manufacturing precision by preventing ill-fitting issues while still allowing easier removal compared to a fully unitary structure
Solution Approach 2:
The mandrel segments use universal or standardized connection features that can be consistently assembled and disassembled. This multi-functional design ensures proper fit for quality production while enabling straightforward removal operations
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 defects, and maintaining the structural integrity of both the part and the mandrel, while also simplifying the process by using a single splice joint.
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
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.