Interlocking Composite Tool Assembly for Thermal Vacuum Tolerance
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Solution Overview
Problem
Current composite part fabrication tools, typically made of monolithic metal, face challenges such as high fabrication costs, long cycle times, and inability to maintain tolerances under thermal and vacuum conditions, leading to frequent tool replacement and increased production downtime.
Innovation Solution
A multi-piece tool assembly with interlocking joint portions and fasteners, fabricated using additive manufacturing, which self-tightens under heat and maintains vacuum integrity, reducing the need for frequent tool replacement and lowering production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If monolithic metal tools are used for composite part fabrication, then the tools can withstand the weight and rigors of forming, but the fabrication costs are high and cycle times are long
Solution Approach 1:
The tool is divided into multiple segments or pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be fabricated more quickly and at lower cost, while the interlocking joint portions ensure the assembled tool maintains the necessary strength and rigidity to withstand composite part formation processes.
2Strength
If monolithic metal tools are used for composite part fabrication, then the tools can maintain structural integrity, but the fabrication costs are high
Solution Approach 1:
The tool is divided into multiple segments or pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be fabricated more quickly and at lower cost, while the interlocking joint portions ensure the assembled tool maintains the necessary strength and rigidity to withstand composite part formation processes.
3Strength
If monolithic metal tools are used for composite part fabrication, then the tools can withstand vacuum conditions, but the tools deform under thermal and vacuum conditions causing tolerance loss
Solution Approach 1:
The tool is divided into multiple segments or pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be fabricated more quickly and at lower cost, while the interlocking joint portions ensure the assembled tool maintains the necessary strength and rigidity to withstand composite part formation processes.
Solution Approach 2:
The tool assembly is designed to undergo controlled thermal expansion when heated during composite curing. The interlocking joint portions with complementary angles are specifically configured to allow the tool to expand uniformly, preventing deformation that would compromise tolerance or vacuum integrity.
4Productivity
If multi-piece tool assembly with interlocking joints is used, then the fabrication cost and cycle time are reduced, but the joints must maintain vacuum integrity and tolerances under thermal expansion
Solution Approach 1:
The tool assembly is designed to undergo controlled thermal expansion when heated during composite curing. The interlocking joint portions with complementary angles are specifically configured to allow the tool to expand uniformly, preventing deformation that would compromise tolerance or vacuum integrity.
Solution Approach 2:
The interlocking joint portions are formed using additive manufacturing processes that create complex geometries with complementary angles. These joint designs incorporate features that maintain vacuum sealing while accommodating thermal expansion, combining the benefits of rapid fabrication with reliable performance under operating conditions.
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 fabrication of large composite parts by reducing tool fabrication cycle time and allowing for the production of larger composite parts while maintaining design tolerances and vacuum integrity.
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 multi-piece tool assembly with interlocking joint portions and fasteners, fabricated using additive manufacturing, which self-tightens under heat
Data Source
Figure 1
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Figure 3
AI summary
A tool assembly (102) includes a first piece (112), a second piece (114), and a fastener (118, 904). The first piece (112) has a first joint portion (122) including a top surface (136a) and at least a first interlock surface (132). The second piece (114) has a second joint portion (124) configured to interlock with the first joint portion (122). The second joint portion (124) includes a top surface (136b) and at least a second interlock surface (134) that is complementary to the first interlock surface (132). The fastener (118, 904) extends through the first and second joint portions (122, 124). The first interlock surface (132) and the top surface (136a) of the first joint portion (122) form an obtuse angle corner (552) and the second interlock surface (134) and the top surface (136b) of the second joint portion (124) form an acute angle corner (572). The first interlock surface (132) is configured to contact the second interlock surface (134) to inhibit relative movement between the first piece (112) and the second piece (114) along a longitudinal axis (254) of the tool assembly (102).