Inflatable Forming Components for Complex Composite Curvature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current composite aircraft component manufacturing techniques, such as hand lay-up, drape forming, press forming, and automatic fiber placement, face limitations in forming parts with extreme or complex curvature due to strain and wrinkling issues, and are labor-intensive or require expensive equipment.
Innovation Solution
A method and apparatus using inflatable components to press formable material against rigid forming components, allowing for the formation of complex shapes like angled flanges without wrinkling, utilizing a part forming apparatus with inflatable components and pressure sources to compress and shape the material between rigid forming components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional forming methods (hand lay-up, drape forming, press forming, AFP) are used to form composite material into parts with extreme curvature, then the parts can be manufactured, but strain and wrinkling occur in the composite material
Solution Approach 1:
The composite material is pre-plyed and pre-consolidated on a flat or slightly-curved surface before forming. This preliminary consolidation ensures the material is stable and free of wrinkles before it is subjected to extreme curvature, preventing strain and wrinkling during the forming process
Solution Approach 2:
The forming process is divided into separate stages: first consolidating the composite plies on a flat surface, then progressively forming the material into the final complex shape. This segmentation allows each stage to be optimized independently, preventing wrinkling while achieving extreme curvature
2Ease of manufacture
If hand lay-up method is used to apply multiple layers of composite material, then the parts can be formed, but the process becomes labor intensive and requires expensive consumable materials
Solution Approach 1:
The system uses self-aligning fixtures and automated material placement mechanisms that automatically position and consolidate composite plies without requiring manual intervention. The process serves itself by using the material's own properties and the fixture geometry to achieve proper alignment and consolidation
Solution Approach 2:
Manual mechanical application of composite materials is replaced with automated material placement systems that use controlled mechanisms to apply and consolidate plies. This substitution eliminates labor-intensive hand lay-up operations while maintaining manufacturing capability
3Shape
If drape forming or press forming is used to form flanges, then the composite material can be shaped, but only one or two flanges in the same direction can be formed simultaneously
Solution Approach 1:
The forming apparatus is divided into multiple independent forming zones, each capable of forming flanges in different directions simultaneously. Each zone operates independently, allowing complex multi-directional flange configurations to be created in a single forming operation
Solution Approach 2:
The system transitions from forming flanges in a single plane to forming flanges in multiple dimensions and directions simultaneously. By adding vertical and angular dimensions to the forming capability, the system can create complex three-dimensional flange structures that extend in multiple directions at once
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 the efficient formation of complex-curved aircraft parts by preventing wrinkling and buckling, reducing material distortion and equipment costs, while allowing for the formation of flanges in multiple directions simultaneously.
Implementation Method 1
actuating expansion of one or more inflatable components, such that the inflatable components press flange portions of the formable material against the rigid forming component
Data Source
AI summary
An apparatus and method configured for manufacturing an aircraft part from formable material. The apparatus may include one or more rigid forming components onto which the formable material is placed and between which non-flange portions of the formable material may be compressed, and at least one inflatable component that, when expanded by inflation, presses flange portions of the formable material against at least one of the rigid forming components. The inflation component(s) may be arranged in any configuration for forming the formable material into C-shaped channels, single L-shaped channels, or opposing Z-shaped channels. Once pressed between the rigid forming components and/or the inflated inflatable components, the formable material may be heated for forming according to the particular formable material used.