Part Contouring with Virtual Index Sections to Prevent Distortion
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Solution Overview
Problem
Traditional shaping methods for parts, particularly those with closed-formed shapes, result in distortions such as pillowing or filleting, leading to gaps and inefficiencies in assembly, increased manufacturing time, and material erosion risks.
Innovation Solution
A system using a contouring unit with actuators and a measuring unit to apply forces to a virtual index section of a part, adjusting forces based on measured physical characteristics to achieve a target shape, and refining a nominal stiffness model for precise shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed constraint tooling is used at discrete points, then the part can be shaped at specific locations, but the part distorts between constraint points causing pillowing or filleting
Solution Approach 1:
A virtual index section is introduced as an intermediary between the physical actuators and the part surface. This virtual section allows forces applied at discrete contact points to be mapped and controlled as if acting on a continuous surface, eliminating intermediate section distortion while maintaining shaping accuracy.
Solution Approach 2:
The virtual index section creates a digital copy or representation of the part surface geometry. This virtual model is used to calculate and distribute shaping forces across the entire surface, preventing local distortions that would occur with traditional discrete point constraint methods.
2Device complexity
If actuators are spaced apart along the part, then the tooling structure remains simple, but forces are not applied at intermediate sections leading to shape distortions
Solution Approach 1:
The virtual index section serves as a computational intermediary that bridges the gap between sparsely distributed physical actuators and the continuous surface requiring shaping. It enables precise force distribution calculations that account for intermediate sections without requiring physical actuators at every location.
3Manufacturing precision
If manual shimming is performed to correct gaps, then assembly accuracy can be improved, but manufacturing time increases and skilled technicians are required
Solution Approach 1:
The shaping system performs preliminary action by correcting part geometry distortions before assembly occurs. By applying forces through the virtual index section to eliminate pillowing and filleting in advance, the part arrives at assembly ready for direct fastening without requiring time-consuming manual shimming operations.
4Ease of manufacture
If gaps occur between parts, then assembly can still be completed with shims, but the final assembly quality deteriorates with increased drag and material erosion risks
Solution Approach 1:
The system performs preliminary shaping to eliminate geometric defects that would create gaps between assembled parts. By correcting distortions in the index section before assembly, the final assembly achieves high quality surfaces without gaps, eliminating drag and material erosion risks while maintaining ease of manufacture.
Data Source
AI summary
Methods and devices of shaping a part during a manufacturing process. The devices include a contouring unit that applies a force to one or more contact points of an index section of the part, and a measuring unit that measures a shape of a virtual index section of the part. The methods include applying a force to the index section of the part and shaping the separate the virtual index section of the part. The shaping can shape the virtual index section to a target shape.