Flexible Mold for Composite Part Extraction
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Solution Overview
Problem
The manufacturing of composite parts with geometries extending over large angular zones, such as the O-Duct type thrust reverser cowl for turbojet engines, is complex and costly due to the need for multiple, heavy, and unreliable mold parts that are difficult to assemble, disassemble, and handle, leading to increased cycle time and risk of damage.
Innovation Solution
A set of tools featuring a flexible mold with a convex surface that can alternate between a working position and a retracted position, allowing for the production of composite parts with convex surfaces using a single mold, reducing the complexity and cost of the manufacturing process by facilitating the extraction of the part without the need for sectorized key tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple heavy mold parts are used to manufacture composite parts with large angular zones, then the part can be extracted from the mold, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The mold incorporates a movable section that can change its position between a first position during manufacturing and a second position for part extraction. This dynamic capability allows a single mold to perform both manufacturing and extraction functions, eliminating the need for multiple heavy mold parts while maintaining the ability to extract complex geometric parts.
Solution Approach 2:
The single mold with movable section serves multiple functions: it maintains geometric support during manufacturing and enables part extraction by changing position. This multi-functionality replaces the need for separate heavy mold parts, reducing device complexity while achieving both manufacturing and extraction objectives.
2Ease of operation
If multiple mold parts are used, then the part can be extracted, but the manufacturing cycle time increases due to assembly and disassembly operations
Solution Approach 1:
The movable section integrates extraction capability directly into the mold structure, allowing position change without complete disassembly. This dynamic repositioning eliminates time-consuming assembly and disassembly operations between manufacturing and extraction, significantly reducing manufacturing cycle time.
3Manufacturing precision
If sectorized key tools are used, then the part can be manufactured, but the risk of damage and handling challenges increase
Solution Approach 1:
The mold is divided into a fixed section and a movable section that can be independently positioned and handled. This segmentation allows the movable section to be carefully controlled during extraction, reducing handling risks while maintaining the ability to form complex convex surfaces that would require sectorized tools.
Solution Approach 2:
The movable section provides controlled, dynamic adjustment capability that replaces the need for multiple rigid key tools. This single integrated movable section reduces the number of handling operations and potential damage points compared to sectorized key tools, improving reliability while achieving the same manufacturing precision.
Data Source
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AI summary
The invention relates to a tool assembly (1) for manufacturing a part made of a composite material (28) including at least one convex surface, including at least one mould (3) at least partially defining the lines of said convex surface and shaped so as to support, in a working position, at least one drape-moulding and polymerisation operation for said part. The tool assembly is characterised in that the mould has at least one flexible portion (4, 33) alternating between said first working position and a second so-called withdrawn position, in which the mould is in a retracted position relative to the working position thereof. The invention also relates to the method for manufacturing a part made of a composite material using the tool assembly according to the invention.