Mandrel Package Manufacturing Apparatus for Composite Stringers
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Solution Overview
Problem
Conventional composite stringer manufacturing processes are time-consuming due to multiple assembly processes, and the use of solid mandrels in closed cross-section composite structures makes tool removal difficult, limiting aircraft production efficiency.
Innovation Solution
A mandrel package manufacturing apparatus that includes a mandrel wrapped with a composite wrap ply and radius fillers, consolidated using vacuum pressure, allowing for efficient formation and removal of composite stringers with a hat-shaped cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional composite stringer manufacturing processes are used, then composite stringers can be attached to composite skin, but the manufacturing time is excessive due to multiple assembly processes
Solution Approach 1:
The patent combines multiple assembly processes (placing stringer components, compaction, and curing) into a single integrated tool that performs all operations simultaneously. The tool includes multiple cavities for different stringer components and a unified compaction mechanism that consolidates all stringers and skins in one curing cycle, eliminating sequential processing steps and reducing total manufacturing time.
Solution Approach 2:
The manufacturing tool is designed as a universal fixture that can accommodate multiple different stringer components and configurations within a single tooling system. The tool includes adjustable positioning mechanisms and multiple cavities that can be configured for various stringer types, allowing one tool to perform multiple assembly operations that would otherwise require separate specialized tools for each operation.
2Manufacturing precision
If solid mandrels are used in closed cross-section composite structures, then the composite structure can be formed, but tool removal becomes difficult
Solution Approach 1:
The solid mandrel is divided into multiple separable segments or sections that can be independently removed from the composite structure. The mandrel includes longitudinal divisions or breakable joints that allow it to be split into smaller pieces, enabling extraction from closed cross-section cavities without requiring complete disassembly of the cured composite structure.
Solution Approach 2:
The mandrel incorporates collapsible or deformable sections that can change their physical configuration during removal. The mandrel may include telescoping segments, compressible foam sections, or flexible materials that allow the mandrel to reduce its volume or change shape to pass through tight spaces in the closed cross-section structure, facilitating easier extraction after curing.
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
This method reduces manufacturing time and facilitates the production of composite structures with complex geometries by enabling easier mandrel extraction and improving the efficiency of aircraft component production.
Implementation Method 1
The consolidating mechanism is configured to consolidate the first radius filler, the second radius filler, and the wrap ply to the mandrel. In an example, the consolidating mechanism includes a vacuum bag configured to be sealed to the backing plate. A vacuum is applied to consolidate the mandrel layup to form the compacted mandrel package.
Data Source
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AI summary
An apparatus (500) used to manufacture a mandrel package (100) comprises a die tool (502) to form a partially wrapped mandrel (146); sweep arms (510), movable relative to the die tool (502), to form a wrapped mandrel (124); a radius filler placement mechanism (518) to place a first radius filler (114) and a second radius filler (116) on the wrapped mandrel (124); and a consolidating mechanism (520) to form the mandrel package (100).