Multilayer Fiber Structure Manufacturing with Contoured Tool Transition
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Solution Overview
Problem
Current methods for manufacturing multilayer fiber structures, particularly for complex shapes like aircraft components, face inefficiencies in laying down fiber tapes due to the need for precise shaping and risk of air pockets, wrinkles, and fiber collapse, especially when transitioning from flat to contoured surfaces.
Innovation Solution
A method and tool system that utilize a contoured tool surface with a curved transition region, a support component, and a roller device to lay down fiber tapes efficiently, allowing high-speed deposition and ensuring accurate shaping by bridging the transition region, thereby avoiding air pockets and wrinkles, and maintaining fiber integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber tapes are laid down directly on a contoured tool surface with curved transition regions, then the desired complex shape is achieved, but the deposition speed must be reduced to avoid air pockets, wrinkles, and fiber collapse
Solution Approach 1:
The tool surface is segmented into a flat first surface region and a contoured second surface region, connected by a curved transition region. The flat region allows high-speed deposition while the contoured region provides the final complex shape, separating the deposition function from the forming function.
Solution Approach 2:
Fiber tapes are preliminarily laid down on the flat first surface region where high-speed deposition is possible, before being transferred to the contoured second surface region for final shaping. This preliminary action on a flat surface avoids the quality issues that would occur during direct deposition on curved surfaces.
2Productivity
If fiber tapes are laid down at high speed on a flat surface, then deposition efficiency is improved, but the final complex shape cannot be achieved
Solution Approach 1:
The tool surface is divided into a flat first surface region for high-speed deposition and a contoured second surface region for final shaping. This segmentation allows each region to perform its specific function optimally without compromise.
Solution Approach 2:
The system uses a movable support component that can be positioned and moved along the tool surface. This dynamic positioning allows the flat deposition area to be relocated as needed, maintaining high-speed deposition capability while ultimately achieving the complex contoured shape.
3Shape
If a contoured tool surface is used directly for fiber placement, then the final shape is achieved, but air pockets and wrinkles form during deposition
Solution Approach 1:
The contoured tool surface is segmented into a flat first surface region and a contoured second surface region. Fiber tapes are deposited on the flat region where reliability is high, then transferred to the contoured region for final shaping, avoiding direct deposition on curved surfaces that cause defects.
Solution Approach 2:
The flat first surface region acts as an intermediary surface for fiber deposition. Fiber tapes are first laid down reliably on this flat intermediary surface, then transferred to the final contoured shape, preventing the formation of air pockets and wrinkles.
4Ease of manufacture
If the support component extends over the curved transition region, then fiber tape deposition is facilitated on a flat surface, but the support component complexity increases
Solution Approach 1:
The support component is designed with multi-functionality: it provides a flat support surface for easy fiber deposition, can be positioned and moved along the tool surface, and works in conjunction with the roller device for fiber transfer. This universal design justifies the increased complexity by enabling high-speed, high-quality deposition.
Solution Approach 2:
The support component incorporates dynamic positioning capabilities, allowing it to be moved along the tool surface as needed. This dynamic feature, while adding complexity, enables the flat support surface to be relocated to different positions, maintaining ease of manufacture throughout the deposition process.
Data Source
AI summary
A method for manufacturing a multilayer fiber structure includes providing a receiving surface being formed by a first surface region of a contoured tool surface of a forming tool component and a support surface of a support component. Further, at least one fiber layer is formed on the receiving surface by laying down a plurality of fiber tapes onto the receiving surface. A roller device is positioned so as to press the at least one fiber layer against the tool surface and the support component and the roller device are synchronously moved along a curved transition region connects the first surface region to a second surface region of the tool surface. Thereby the at least one fiber layer is abutted against the transition region and the second surface region of the tool surface. Further, a tool system for manufacturing a multilayer fiber structure is disclosed.