Interlocking Composite Tool Assembly for Thermal Expansion Stability
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Solution Overview
Problem
Current composite part fabrication tools, typically made of monolithic metal, are costly and have long fabrication cycles due to deformation issues under vacuum and high temperature conditions, requiring frequent tool replacement and design iterations.
Innovation Solution
A multi-piece tool assembly with interlock surfaces and fasteners, fabricated using additive manufacturing, which self-interlocks to maintain vacuum integrity and withstand thermal expansion, reducing fabrication costs and cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monolithic metal tools are used for composite part fabrication, then the tools can withstand vacuum and high temperature conditions, but the tools deform under these conditions and require frequent replacement, increasing fabrication costs and cycle times
Solution Approach 1:
The tool is divided into multiple segments or pieces that can be independently manufactured and assembled. This segmentation allows each piece to be optimized for specific conditions and enables replacement of only damaged segments rather than the entire tool, reducing downtime and fabrication cycle times while maintaining reliability.
2Strength
If monolithic metal tools are used for composite part fabrication, then the tools can maintain structural integrity, but the fabrication costs are high due to material and manufacturing requirements
Solution Approach 1:
Dividing the tool into segments reduces material costs and manufacturing complexity. Each segment can be manufactured using more cost-effective processes and materials appropriate for its specific functional requirements, while still maintaining the overall structural integrity needed to withstand vacuum and high temperature conditions during composite part fabrication.
3Manufacturing precision
If monolithic metal tools are used for composite part fabrication, then the tools provide a continuous working surface, but design iterations require complete tool replacement, increasing time and cost
Solution Approach 1:
Segmenting the tool allows individual segments to be independently modified or replaced during design iterations. This provides flexibility to update specific portions of the tool without replacing the entire structure, enabling faster design iterations while maintaining the precise surface contours required for high-quality composite part fabrication.
Solution Approach 2:
The segmented tool structure enables dynamic reconfiguration and adaptation. Segments can be swapped or adjusted to accommodate design changes, making the tool system more versatile and adaptable to different composite part geometries and design requirements while preserving manufacturing precision.
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
The tool assembly enables faster and more cost-effective production of large composite parts by maintaining design tolerances and vacuum integrity, reducing the need for frequent tool replacement and design iterations.
Implementation Method 1
The first interlock surface is configured to contact the second interlock surface to inhibit relative movement between the first piece and the second piece along a longitudinal axis of the tool assembly
Implementation Method 2
a fastener extending through the first and second joint portions
Implementation Method 3
The method further includes applying heat to the tool assembly, where upon heating, interlock surfaces of the first and second joint portions tighten
Data Source
AI summary
A tool assembly includes a first piece, a second piece, and a fastener. The first piece has a first joint portion including a top surface and at least a first interlock surface. The second piece has a second joint portion configured to interlock with the first joint portion. The second joint portion includes a top surface and at least a second interlock surface that is complementary to the first interlock surface. The fastener extends through the first and second joint portions. The first interlock surface and the top surface of the first joint portion form an obtuse angle corner and the second interlock surface and the top surface of the second joint portion form an acute angle corner. The first interlock surface is configured to contact the second interlock surface to inhibit relative movement between the first piece and the second piece along a longitudinal axis of the tool assembly.