Fibre Pre-form Winding Head with Segmented Fingers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming metal matrix composite (MMC) fibre pre-forms, such as TiMMC, face challenges in maintaining precise spacing between plates during the wrapping process, leading to issues like fibre overlap or snagging, especially on larger diameters, due to the requirement for extremely flat and parallel plates, which is costly and limits the size of articles that can be manufactured.
Innovation Solution
A method involving a winding head with radially extending alternate finger members that create an axial spacing less than the fibre diameter, allowing the fibre to bend out of plane and generate friction for secure placement, accommodating diameter variations and preventing overlap, while allowing for the simultaneous winding of multiple fibres with varying tensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extremely flat and parallel plates are used to maintain spacing during wrapping, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The single plate structure is segmented into multiple finger members that are circumferentially spaced. Each finger member independently defines a winding surface, eliminating the need for an entire plate to maintain extreme flatness. The spacing is maintained by the discrete finger structure rather than a continuous plate surface.
Solution Approach 2:
The finger members act as intermediary elements between the plates, providing the necessary spacing and support for fibre winding. Instead of relying on the plates themselves to maintain spacing through extreme flatness, the finger members mediate the spacing function.
2Manufacturing precision
If fixed spacing between plates is maintained, then fibre alignment is improved, but adaptability to fibre diameter variations deteriorates
Solution Approach 1:
The finger members are made resilient, allowing the axial spacing to dynamically adjust as fibres are wound. When fibres with varying diameters are introduced, the resilient fingers can flex to accommodate the diameter changes while maintaining adequate spacing, preventing both overlap and snagging.
Solution Approach 2:
The axial spacing between winding surfaces is designed to be less than the fibre diameter, creating a dynamic system where the effective spacing can vary within acceptable ranges. This parameter design allows the system to adapt to fibre diameter variations (±5 microns) while maintaining proper fibre placement.
3Ease of manufacture
If axial spacing equals fibre diameter, then fibre placement is simplified, but fibre stability deteriorates due to overlap or snagging
Solution Approach 1:
The finger members extend in the axial direction, creating a three-dimensional winding surface structure. This axial extension provides a larger contact area and multiple contact points for the fibre, improving stability through increased friction and mechanical engagement rather than relying solely on precise two-dimensional spacing.
Solution Approach 2:
The finger members are positioned and spaced before the fibre winding process begins. The axial spacing is pre-configured to be less than the fibre diameter, creating the necessary friction and mechanical constraint that prevents fibre overlap and snagging during the winding operation.
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 approach enables the formation of larger fibre composite articles with improved fibre alignment and reduced likelihood of overlap, accommodating diameter variations, and allows for the production of stable pre-forms suitable for reinforcement in gas turbine engine components.
Implementation Method 1
the fibre is caused to bend between each finger out of a radially extending plane, thereby causing an out of plane force. This force provides a friction between the fibre and the winding surfaces, thereby holding the wire in place.
Data Source
AI summary
A method of forming a metal matrix composite (MMC). The method comprises providing a fiber (26) comprising a ceramic material coated with a metal, providing a winding head (12) having a plurality of circumferentially spaced radially extending alternate first and second finger members (18, 20), the finger members each defining a winding surface (22, 24), the winding surface of each first finger member facing a first axial direction, and the winding surface of each second finger member facing a generally opposite axial direction, wherein adjacent winding surfaces (22, 24) of the first and second finger members (18, 20) are spaced in a circumferential direction, and define an axial spacing less than the diameter of the fiber (26), and winding the fiber around the winding head (12) between the winding surfaces (22, 24) of the first and second finger members (18, 20).