3D Woven Fiber Preform Cutting Table for Accurate Profile Cutting

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Solution Overview

Problem

Manual cutting of fiber preforms with non-interlinking zones results in inaccuracies and reproducibility issues, making it difficult to achieve uniform profiles for complex composite material parts like fan blade platforms.

Innovation Solution

A cutting table with a recessed tabletop, sacrificial plates, and a cutting template with compacting pressure, allowing for precise and uniform cutting of fiber preforms by interposing sacrificial plates and applying pressure to prevent deformation and fiber loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual cutting is used to cut out profiles from fiber preforms, then flexibility to handle different shapes is maintained, but cutting accuracy and reproducibility deteriorate

Engineering Contradiction:

Improveflexibility to handle different shapesVSAvoidcutting accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent uses physical templates that replicate the desired profile shapes. These templates serve as accurate copies of the target geometry, allowing precise reproduction of complex shapes without manual measurement and cutting, thereby resolving the contradiction between flexibility and accuracy.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The templates are prepared in advance with precise dimensions and shapes. This preliminary action of creating accurate templates before cutting eliminates the need for real-time manual adjustments, ensuring consistent cutting accuracy across different production runs while maintaining the ability to handle various shapes.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If manual cutting is used on fiber preforms, then operator judgment can be applied, but fiber loss and deformation increase

Engineering Contradiction:

Improveoperator judgmentVSAvoidfiber loss

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The template acts as an intermediary between the operator and the cutting process. It provides fixed reference edges and positioning features that guide the cutting tool, eliminating the need for operator judgment during cutting while preventing fiber loss through precise template-guided cuts.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the manual judgment-based mechanical cutting process with a template-guided system. The template's physical features (edges, positioning elements) substitute for operator judgment, providing consistent guidance that prevents fiber damage and loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If waterjet cutting is used for uniform profiles, then cutting speed is improved, but it cannot handle non-uniform profiles of preforms with non-interlinking zones

Engineering Contradiction:

Improvecutting speedVSAvoidability to handle non-uniform profiles

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent divides the cutting process into segments: waterjet pre-cutting for the common outline (high speed), followed by template-guided manual cutting for the specific portion profiles (high precision). This segmentation allows each method to operate in its optimal range, combining speed and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The waterjet performs preliminary cutting of the common outline before the template-guided process. This preliminary action removes the bulk material quickly, leaving only the final precision cutting to be done by the template method, thereby combining the advantages of both approaches.

Inventive Principle:

Principle #10Preliminary action

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 solution enables accurate and reproducible cutting of fiber preforms with reduced risk of injury and deformation, facilitating the production of complex composite parts with precise profiles.

Implementation Method 1

means for applying compacting pressure against the cutting template

Methodology Applied

Scientific EffectCompressing: Compression

Data Source

PatentUS10239223B2Cutting table for cutting a fiber preform obtained by three-dimensional weaving, and a cutting method using such a table

Publication Date: 2019.03.26 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A cutting table for cutting out a fiber preform obtained by three-dimensional weaving and having two portions that are connected together by at least one zone of non-interlinking and that present outlines of different shapes, includes a tabletop provided with a recess for receiving one of the portions of the fiber preform to be cut out. The fiber preform is capable of laying flat in the access. The cutting table further includes sacrificial plates for interposing between the portions of the fiber preform for cutting out and for being fastened to the tabletop. The sacrificial plates are capable of covering partially the recess of the tabletop while being fastened to the tabletop. The cutting table also includes a cutting template configured to be pressed against a portion of the fiber preform that is positioned outside of the recess, and a device for applying compacting pressure against the cutting template.