Expandable Male Tool for 3D C/C Composite Forming
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Solution Overview
Problem
Existing methods for manufacturing carbon/carbon (C/C) composites, particularly in aerospace applications, often result in low interlaminar properties due to the production of 2D planar structures, which lack the structural integrity and performance required for high-temperature conditions.
Innovation Solution
A shape forming tool system comprising a female forming tool and an expandable male die arrangement with an expander tool, such as a cam shaft, is used to form C/C composites, allowing for the creation of 3D structures with improved interlaminar properties by applying lateral forces and maintaining pressure during pre-carbonization compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional 2D planar structures are used for C/C composites, then manufacturing simplicity is maintained, but interlaminar properties and structural integrity deteriorate
Solution Approach 1:
The male die is divided into multiple expandable segments or blades that can independently move laterally. This segmentation allows the forming tool to create complex 3D structures while maintaining manageable complexity in each individual segment, thereby improving interlaminar properties through 3D architecture without overwhelming device complexity
Solution Approach 2:
The male die transitions from a static 2D structure to a dynamic expandable structure. The expander tool enables the male die to dynamically change its configuration, moving laterally to form 3D structures. This dynamic capability allows the creation of complex geometries with superior interlaminar properties while the expander mechanism manages the overall system complexity
2Reliability
If expandable male die arrangement is used to create 3D structures, then interlaminar properties are improved, but device complexity increases
Solution Approach 1:
The male die is segmented into multiple controllable sections that can expand and contract independently. This segmentation enables the formation of complex 3D structures with improved structural integrity and interlaminar properties, while each segment remains a manageable component, preventing excessive overall device complexity
Solution Approach 2:
An expander tool acts as an intermediary mechanism between the operator and the male die. This intermediary device controls the lateral movement of the male die segments, enabling complex 3D structure formation with improved reliability while the expander mechanism itself manages and organizes the complexity of the system
3Shape
If lateral forces are applied during forming, then 3D structure formation is enabled, but manufacturing complexity increases
Solution Approach 1:
The male die is designed with dynamic expandability, allowing it to apply lateral forces and transform from a 2D to a 3D configuration during the forming process. This dynamic capability enables complex 3D structure formation while the controlled expansion mechanism maintains manufacturing feasibility
Solution Approach 2:
The expander tool utilizes pneumatic or hydraulic mechanisms to generate and control lateral forces on the male die. This approach enables precise control of the expansion process and 3D structure formation, while fluid power systems provide a relatively simple and efficient method for generating the required forces compared to purely mechanical alternatives
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 system enables the production of C/C parts with enhanced structural integrity and high-temperature performance, suitable for aerospace applications, by forming 3D structures with superior interlaminar properties compared to traditional 2D planar components.
Implementation Method 1
The first expander tool is configured to move the first die half laterally toward a first side of the first shape forming tool sub-assembly away from the second die half. The first expander tool is further configured to move the second die half laterally toward a second side of the first shape forming tool sub-assembly away from the first die half.
Implementation Method 2
In various embodiments, the first expander tool comprises a cam shaft.
Data Source
AI summary
A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a first die half configured to be received by the die recess, a second die half configured to be received by the die recess, an expander tool coupled between the first die half and the second die half. The expander tool is configured to move the first die half laterally toward a first side of the female forming tool away from the second die half to compress the fibrous preform between the first die half and the female forming tool. The expander tool is further configured to move the second die half laterally toward a second side of the female forming tool away from the first die half to compress the fibrous preform between the second die half and the female forming tool.