Fluidly Actuated Support for Composite Surface Contouring
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Solution Overview
Problem
Current methods for constructing composite structures with non-planar surface contours are inefficient and prone to buckling or wrinkling, especially in complex applications like aircraft construction, where deformation can lead to undesirable shapes that preclude the use of conventional drape forming processes.
Innovation Solution
A forming system comprising a forming die, a fluidly actuated support, and a vacuum bag, where the fluidly actuated support transitions between extended, intermediate, and retracted conformations in response to fluid flow or pressure differentials, allowing for precise deformation of layered charges to define desired surface contours while maintaining contact with the forming die and support surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drape-forming processes are used to form layered charges on a flat surface and then deform them to a final shape, then productivity is improved by avoiding layer-by-layer assembly, but manufacturing precision deteriorates due to undesired buckles and wrinkles in the layered charge
Solution Approach 1:
The forming die is pre-configured with the desired surface contour geometry before the layered charge is placed. The layered charge is initially laid up on a flat or simplified mandrel, and then the forming die is engaged to progressively deform the charge to the final contoured shape, preventing buckles and wrinkles from forming during the process
Solution Approach 2:
A forming die acts as an intermediary tool between the layered charge and the final contoured shape. The die provides a controlled deformation mechanism that gradually shapes the material, ensuring uniform stress distribution and preventing localized buckling or wrinkling that would occur with direct drape forming
2Manufacturing precision
If layer-by-layer assembly is used on a layup mandrel to construct composite structures with non-planar surface contours, then manufacturing precision is maintained through controlled placement, but productivity deteriorates due to significant time requirements for complex structures
Solution Approach 1:
Multiple layers of composite material are pre-assembled on a flat or simplified mandrel in a batch operation, creating a complete layered charge ready for forming. This preliminary assembly step allows for more efficient material placement before the final contoured shape is imposed through the forming die
Solution Approach 2:
The manufacturing process is segmented into two distinct phases: (1) batch layering of material on a flat surface, and (2) subsequent forming to the final contoured shape. This segmentation allows each phase to be optimized independently, improving overall productivity while maintaining precision
3Productivity
If conventional drape forming is used to deform layered charges to a final shape, then productivity is improved by reducing assembly time, but reliability deteriorates due to buckles and wrinkles that preclude use in certain applications
Solution Approach 1:
The forming die serves as a controlled intermediary that mediates the deformation process between the layered charge and the final shape. It distributes forming forces uniformly across the material, preventing localized stress concentrations that cause buckles and wrinkles, thereby ensuring structural integrity
Solution Approach 2:
The forming process is made dynamic and controllable through the forming die, which can be adjusted or programmed to apply deformation in a controlled sequence. This dynamic control allows the material to be gradually shaped without sudden stress applications that would cause defects, maintaining both speed and reliability
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 method enables the efficient and accurate formation of complex composite structures by controlling the deformation of layered charges, reducing the risk of buckling and wrinkling, and allowing for the creation of non-planar surface contours suitable for aerospace applications.
Implementation Method 1
a vacuum source that is configured to selectively apply a vacuum to the enclosed volume
Implementation Method 2
the fluidly actuated support includes and/or is a foam body configured to transition among an extended conformation, an intermediate conformation and/or a retracted conformation responsive to a fluid flow and/or responsive to a pressure differential
Data Source
Figure 1~2
Figure 3
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AI summary
Systems and methods for defining a surface contour of a layered charge (90) of material are disclosed herein. The systems include a forming die (30), which includes a forming surface shaped to define a desired surface contour (94) of the layered charge, and a fluidly actuated support (50), which includes a support surface that is adjacent to the forming surface and located to support the layered charge (90). The systems further include a vacuum bag (70) that at least partially defines an enclosed volume and a vacuum source configured to selectively apply a vacuum to the enclosed volume. The methods include locating the layered charge (90) on the forming surface (40) and on the support surface (60), covering the layered charge with the vacuum bag (70) to define the enclosed volume, applying the vacuum to the enclosed volume, compressing the fluidly actuated support (50), translating the support surface (60), and deforming the layered charge (90) to define the desired surface contour.