Fiber-Plastic Composite Reference Body for Delamination Simulation
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Solution Overview
Problem
Existing methods for simulating delamination in fiber-plastic composite (FPC) components, particularly in aircraft components, are inadequate as they often require foreign bodies that distort measurement results, making it difficult to accurately detect and calibrate delamination defects.
Innovation Solution
A method involving the creation of FPC reference bodies with precured inserts and clearances in FPC films, where the inserts are inserted into corresponding clearances and cured without foreign bodies, simulating delamination by utilizing the capillary effect to prevent connecting means from entering the recess, thus mimicking the separation of FPC layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If foreign bodies are used to simulate delamination in FPC components, then the delamination can be simulated, but the measurement results are distorted and accuracy is reduced
Solution Approach 1:
The patent uses FPC material that is homogeneous with the surrounding composite material to create the delamination simulation. The insert is made from the same or similar FPC material as the host component, ensuring that the simulation region is indistinguishable from natural defects during nondestructive testing, thereby eliminating measurement distortion caused by foreign bodies
Solution Approach 2:
The patent creates a realistic copy of a natural delamination defect by using precured inserts with recesses that replicate the physical and electromagnetic characteristics of actual delamination. This copying approach allows the reference body to accurately simulate defect behavior without introducing foreign material artifacts
2Manufacturing precision
If expansion bodies are used to simulate component defects, then delamination can be generated, but foreign bodies remain in the component distorting measurements
Solution Approach 1:
The patent extracts the harmful foreign body from the simulation process by using precured inserts made of FPC material instead of expansion bodies. The insert is inserted into a clearance and cured in place, eliminating the need for expansion bodies that would remain as foreign objects and distort subsequent measurements
Solution Approach 2:
The patent changes the material parameter of the simulation insert from foreign material to homogeneous FPC material. This parameter change ensures that the insert has similar electromagnetic and physical properties to the surrounding composite, preventing measurement distortion while maintaining defect simulation capability
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
Enables realistic simulation of delamination without foreign bodies, allowing for precise measurement and calibration of FPC components, particularly in the aviation industry, by generating measurement results that closely resemble natural delamination defects, enhancing the accuracy of nondestructive testing.
Implementation Method 1
utilizing the capillary effect to prevent connecting means from entering the recess
Data Source
AI summary
The invention relates to a method for producing a fiber-plastic composite reference body for simulating delamination for the nondestructive testing of FPC components, in particular aircraft components, comprising the following steps: i. producing a first insert by a. arranging a first FPC layer; b. forming a recess in the first FPC layer; c. procuring the first FPC layer, in order to obtain the first insert; ii. producing a second insert by a. arranging a second FPC layer; b. pre-curing the second FPC layer, in order to obtain the second insert; iii. providing at least one first FPC layer and at least one second FPC layer with a first clearance and a second clearance; iv. inserting the first insert and the second insert into the respective clearance of the corresponding FPC layer; v. curing the arrangement, a delamination being simulated at the recess of the first insert.