Continuous Compression Molding Composite Body Interchangeable Dies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for manufacturing composite structural supports, such as stringers for gas turbine engines, are time-consuming, laborious, and costly, especially when design changes like curvature or cross-sectional geometry are required, as they often necessitate new molds and manual lay-up of prepreg material.
Innovation Solution
A method involving continuous compression molding using interchangeable dies within a compression molding tool to shape and consolidate prepreg material, allowing for efficient production of composite bodies with varying configurations, including curvature and cross-sectional geometries, by swapping dies to change the shape and size of the composite body portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to manufacture composite structural supports with design changes, then manufacturing precision can be maintained, but productivity decreases and loss of time increases
Solution Approach 1:
The mold is divided into interchangeable die sets, each configured for a specific geometry. This segmentation allows rapid switching between different product configurations without retooling the entire manufacturing system, thereby maintaining precision while improving productivity.
Solution Approach 2:
The manufacturing system becomes dynamic through the ability to swap die sets during production. This dynamism enables the system to adapt to different production requirements efficiently, resolving the contradiction between maintaining precision and improving productivity.
2Manufacturing precision
If traditional methods are used to manufacture composite structural supports with design changes, then manufacturing precision can be maintained, but loss of time increases
Solution Approach 1:
Multiple die sets are prepared in advance, each pre-configured for a specific geometry. This preliminary preparation eliminates the need for time-consuming reconfiguration during production, maintaining precision while reducing time loss.
Solution Approach 2:
The ability to dynamically swap between pre-prepared die sets reduces the time penalty associated with design changes, while the precision is maintained through the use of purpose-built dies for each configuration.
3Productivity
If interchangeable dies are used to enable design changes, then productivity improves and loss of time decreases, but device complexity increases
Solution Approach 1:
The overall mold system is segmented into modular die sets that can be independently swapped. This segmentation manages complexity by breaking down the complex tooling system into manageable, interchangeable units.
Solution Approach 2:
The mold assembly is designed as a universal system that can accommodate multiple die sets. This multi-functionality allows a single base structure to serve multiple purposes, improving productivity without proportionally increasing complexity.
4Manufacturing precision
If manual lay-up of prepreg material is used, then manufacturing precision can be maintained, but ease of manufacture decreases and productivity decreases
Solution Approach 1:
The manual mechanical lay-up process is replaced with automated placement mechanisms within the compression mold. This substitution maintains precision through controlled material placement while significantly improving ease of manufacture and productivity.
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 automates the manufacturing process, reduces costs associated with design changes, and enables the efficient production of composite structural supports with complex geometries, improving production efficiency and reducing labor costs.
Implementation Method 1
The shaped first longitudinal portion of the continuous length of prepreg material is consolidated using the compression molding tool
Implementation Method 2
consolidated using the compression molding tool
Data Source
AI summary
A method is provided for manufacturing a composite body. A first longitudinal portion of a continuous length of prepreg material is shaped using a first die of a compression molding tool to provide a shaped first longitudinal portion of the continuous length of prepreg material. The shaped first longitudinal portion is consolidated using the compression molding tool to provide a first portion of the composite body. The first portion of the composite body is moved out of the compression molding tool. The first die is swapped for a replacement first die. A second longitudinal portion of the continuous length of prepreg material is shaped using the replacement first die of the compression molding tool to provide a shaped second longitudinal portion of the continuous length of prepreg material. The shaped second longitudinal portion is consolidated using the compression molding tool to provide a second portion of the composite body.