Indexing Bolt With Tapered Alignment for Composite Form Assemblies
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Solution Overview
Problem
High-precision composite manufacturing requires connections between form pieces with tolerances tighter than what standard threaded fasteners can achieve, due to the tight geometries and high precision needed in aerospace manufacturing.
Innovation Solution
An indexing bolt with a shank having a first barrel portion, a second barrel portion, and an indexing section between them, featuring a tapered portion that seats within a tapered opening of an alignment plate, allowing for precise alignment and connection of form assemblies with adjustable retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard threaded fasteners are used to join form pieces, then ease of manufacture and operation are improved, but manufacturing precision deteriorates due to threading play greater than 0.001 inch
Solution Approach 1:
The indexing bolt is divided into distinct functional sections: a non-threaded indexing section with tapered portion for precision alignment, and threaded barrel sections for clamping and adjustment. This segmentation allows each section to perform its specific function optimally without interference from other functions.
Solution Approach 2:
The non-threaded indexing section with tapered portion acts as an intermediary element between the threaded fastening sections and the form pieces. It mediates the alignment function, providing precise positioning (0.001 inch tolerance or better) that is then maintained during the clamping process.
2Adaptability or versatility
If multiple bolt sizes are maintained in inventory to accommodate faceplate thickness variations, then adaptability is improved, but device complexity and inventory management worsen
Solution Approach 1:
The indexing bolt is designed as a universal fastener that can accommodate multiple faceplate thicknesses through its adjustable retainer mechanism. The threaded barrel portion allows the retainer to be positioned at different locations along the bolt length, enabling the same bolt to adapt to various thickness variations without requiring multiple bolt sizes.
Solution Approach 2:
The retainer is made movable along the threaded barrel portion, allowing dynamic adjustment of the bolt's effective length and clamping position. This dynamic adjustability enables a single bolt design to handle a range of faceplate thicknesses, eliminating the need for static inventory of multiple bolt sizes.
3Manufacturing precision
If field machining is performed to achieve precise alignment, then manufacturing precision is improved, but loss of time and productivity worsen
Solution Approach 1:
The tapered portion of the indexing section is pre-configured with precise geometry during manufacturing. This preliminary precision machining of the indexing section eliminates the need for field machining of the form pieces, as the pre-made tapered feature directly provides the necessary alignment when inserted into the corresponding tapered opening in the alignment plate.
Data Source
AI summary
A connection between form assemblies of a form for a composite part is disclosed. The connection includes an indexing bolt for connecting first and second form assemblies of a form for a composite part to one another. The indexing bolt includes a head and a shank extending from the head. The shank has a first barrel portion, a second barrel portion spaced apart from the first barrel portion, and an indexing section extending between the first barrel portion and the second barrel portion. The indexing section includes a tapered portion that is receivable within the tapered opening of the alignment plate of the second form assembly. The first barrel portion has a first diameter and the second barrel portion has a second diameter. The first diameter is different than the second diameter. The first and second barrel assemblies each include external threading.