Multi-Movement Stamping Tool for Uniform Composite Flange Compaction
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Solution Overview
Problem
Existing stamping tools with mobilities fail to uniformly compact composite blanks with thermoplastic matrix and continuous fibrous reinforcement, particularly when forming parts with pinched flanged edges, due to non-uniform compaction pressure and inability to adjust the degree of compaction precisely.
Innovation Solution
A stamping tool with a punch comprising a central part and movable lateral parts that expand laterally upon striking, controlled by springs and adjustable abutments, allowing precise compaction and shaping of parts with pinched flanged edges by translating the lateral parts perpendicular to the striking direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed punch is used for stamping composite blanks, then the stamping operation is simple, but uniform compaction of flanged edges cannot be achieved
Solution Approach 1:
The punch is divided into a fixed central part and movable lateral parts that can independently translate perpendicular to the striking direction. This segmentation allows different regions of the punch to perform different functions: the central part provides the striking motion while the lateral parts provide the compaction motion, resolving the contradiction between simplicity and uniform compaction capability.
Solution Approach 2:
The lateral parts of the punch are made movable rather than fixed, allowing them to translate dynamically during the stamping operation. This dynamic capability enables the punch to adapt to the geometry of pinched flanged edges and achieve uniform compaction throughout the flanged edges, including regions that would be inaccessible to a fixed punch.
2Manufacturing precision
If lateral parts are made movable to achieve uniform compaction, then compaction quality improves, but device complexity increases
Solution Approach 1:
The lateral parts are designed with mobility mechanisms that allow controlled translation perpendicular to the striking direction. This dynamic capability enables precise control of the compaction process and thickness of flanged edges while maintaining a relatively simple overall structure through the use of straightforward mechanical linkages.
Solution Approach 2:
The movable lateral parts serve multiple functions: they provide compaction pressure, control the thickness of flanged edges, and adapt to varying geometries of pinched edges. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while achieving precise thickness control.
3Adaptability or versatility
If the punch width is reduced to fit pinched edges, then parts with complex geometries can be produced, but compaction pressure is insufficient
Solution Approach 1:
The lateral parts are designed to translate outward perpendicular to the striking direction during the compaction phase, allowing the effective width of the punch to increase dynamically. This enables the punch to maintain contact with and apply sufficient compaction pressure to the full width of pinched flanged edges, resolving the contradiction between geometry adaptation and compaction force.
Solution Approach 2:
The mobility mechanism is pre-configured to automatically translate the lateral parts outward when needed, without requiring external control or adjustment during the operation. This preliminary setup ensures that the punch automatically adapts to the full width of pinched edges and applies adequate compaction pressure, eliminating the trade-off between geometry adaptation and force.
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 production of high-quality composite parts with precise thickness control and uniform compaction, reducing material waste and assembly requirements, suitable for manufacturing aircraft wing ribs and other structural components with complex edge geometries.
Implementation Method 1
pressure means acting on the at least two movable lateral parts to urge them against the central part
Implementation Method 2
the central part comprising an end located between the at least two movable lateral parts and forming a wedge between the at least two lateral parts
Implementation Method 3
a further displacement of the central portion in the striking direction relative to the at least two movable lateral parts causes the displacement of at least two movable lateral parts relative to each other in a translation towards the side walls of the imprint
Data Source
AI summary
The invention relates to a tooling for stamping a composite blank with a thermoplastic matrix and continuous fibrous reinforcement, and a stamping method using such a tooling, the tooling comprising:a die comprising an imprint (110) having a bottom (111) and side walls (112);a punch (120) the external shape of which is paired with the imprint of the die and comprising a central part (123) and at least two lateral movable parts (121, 122) in sliding connection with the central part (123), so that the movable lateral parts being stopped in translation according to a striking direction (190) against the bottom of the die, a further displacement of the central part (123) in the same direction causes the movable lateral parts to move in translations perpendicular to the striking direction (190).