Multi-Layer Preform Shaping with Asynchronous Peripheral Grips
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Solution Overview
Problem
Existing methods for forming preforms into shaped bodies in aerospace applications are in need of improvement to enhance efficiency and reduce deformation during the forming process.
Innovation Solution
A manufacturing method involving a preform arranged with grips along its periphery, where the grips asynchronously grip the stack of layers during pressing, and the orientation of the top die relative to the bottom die changes during the forming process, using a system with a bottom die and a top die that engage the layers of material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pressing methods are used to form preforms into shaped bodies, then the forming process can be completed, but deformation and bunching of layers occur
Solution Approach 1:
The pressing operation is segmented into multiple stages with different die configurations. The system uses a first die for initial pressing and a second die with a recess for final forming, allowing the preform to be gradually deformed into the shaped body without sudden deformation that causes bunching and layer misalignment.
Solution Approach 2:
The pressing process employs dynamic adjustment of die orientation and positioning. The top die changes its orientation relative to the bottom die during the pressing operation, and the grips are asynchronously activated to dynamically control the deformation process, preventing layer bunching and maintaining precision.
2Reliability
If synchronous gripping is used during pressing, then the preform is securely held, but deformation and bunching of layers occurs
Solution Approach 1:
The grips are activated asynchronously in a sequential manner rather than simultaneously. Each grip is activated at different time intervals during the pressing operation, allowing controlled deformation at different locations while maintaining overall stability through periodic gripping actions.
3Ease of manufacture
If fixed die orientation is used during pressing, then the forming process is simple, but the preform deforms unevenly causing bunching
Solution Approach 1:
The die system employs dynamic orientation changes where the top die adjusts its angle and position relative to the bottom die during the pressing operation. This dynamic adjustment ensures uniform deformation distribution across the preform, preventing bunching while maintaining a relatively simple forming process.
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 method reduces deformation and bunching of layers by allowing differential movement and synchronized gripping, resulting in a more precise and efficient formation of shaped bodies.
Implementation Method 1
The first die is configured to press the stack of the layers of material into the recess
Implementation Method 2
The grips are configured to selectively grip the stack of the layers of material as the first die presses the stack
Data Source
AI summary
During a manufacturing method, a preform is arranged with a plurality of grips. The preform includes a stack of a plurality of layers of material. The grips are disposed along a periphery of the stack. The preform is formed into a shaped body. The forming includes pressing a die against the stack and gripping the stack with the grips during the pressing of the die. The gripping includes asynchronously gripping the stack with at least some of the grips.