Annular Composite Ply Forming with Pivoted Feed for Complex Curves
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Solution Overview
Problem
Fabricating composite structures with complex, curved shapes and varying surface features using fiber-reinforced materials is challenging due to the formation of defects like wrinkles and the difficulty in achieving desired strength and weight characteristics, leading to costly and time-consuming processes with less than optimal results.
Innovation Solution
An automated method and apparatus for forming composite structures with an annular shape, involving a forming tool with varying radii of curvature and a material feed assembly that pivots to apply fibers offset relative to the tool's surface, allowing for gradual changes in diameter and curvature, thereby conforming the material without cutting or darting, which reduces defects and enhances structural performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hand lay-up with intermediate debulkings is used to fabricate annular-shaped composite structures, then complex curved shapes can be achieved, but the process becomes costly and time-consuming with less than desired results
Solution Approach 1:
The patent applies preliminary action by pre-forming the composite structure on a mandrel with the desired complex curved shape before final curing. The mandrel is designed with the target geometry, allowing the material to be shaped in advance rather than requiring iterative hand lay-up and debulking operations during fabrication.
Solution Approach 2:
The patent uses a mandrel as an intermediary tool that transfers the desired complex curved shape to the composite structure. The mandrel acts as a mediator between the flat material and the final complex shape, enabling automated forming while maintaining geometric fidelity without requiring manual intervention.
2Ease of manufacture
If conventional forming methods are used for complex curved structures, then fabrication can proceed, but defects such as wrinkles or waves form that weaken the parts
Solution Approach 1:
The patent applies dynamics by using a movable, adjustable forming tool that can dynamically adapt to the material flow during forming. The tool includes adjustable rollers and belts that can move independently to accommodate varying curvature requirements, preventing wrinkle formation while maintaining structural integrity through controlled, dynamic adjustment rather than static forcing.
Solution Approach 2:
The patent changes physical parameters by controlling temperature, pressure, and material feed rate during the forming process. The system adjusts these parameters dynamically to match the local curvature requirements, preventing defect formation by optimizing the forming conditions for each specific geometric region rather than using constant parameters throughout.
3Shape
If plies are cut or darted to conform to desired shape, then complex shapes can be achieved, but the structural characteristics and performance are degraded
Solution Approach 1:
The patent applies segmentation by dividing the forming process into multiple sequential stages, each handling a specific portion of the shape transformation. Instead of cutting the material, the process segments the deformation into controlled steps that maintain fiber continuity, preserving structural characteristics while achieving complex shapes through progressive forming.
Solution Approach 2:
The patent uses composite materials with specific properties that enable forming without cutting. The material system is selected to have appropriate ductility and fiber-matrix bonding characteristics that allow it to be formed into complex shapes while maintaining fiber continuity and structural integrity, eliminating the need for darting or cutting operations.
4Productivity
If automated processes are implemented for composite forming, then productivity increases, but achieving complex curved shapes with varying surface features becomes difficult
Solution Approach 1:
The patent applies dynamics by implementing an automated forming tool with multiple degrees of freedom that can dynamically adjust to varying surface features. The system includes movable rollers, adjustable belts, and programmable positioning systems that automatically adapt to complex geometries without requiring manual intervention, maintaining both high productivity and geometric fidelity.
Solution Approach 2:
The patent implements feedback control by using sensors to monitor the forming process in real-time and automatically adjusting forming parameters to maintain accuracy on complex surfaces. The feedback system detects deviations from the target geometry and automatically corrects them, enabling automated processing of parts with varying surface features while maintaining high precision.
Data Source
AI summary
Methods of forming a composite structure include conforming at least one ply of material to a forming surface of a tool having differing features. Apparatuses for forming a composite structure include a forming tool and a material feed assembly configured to hold a supply of material, where the material feed assembly may be configured to pivot the supply of material relative to the forming tool. Composite structures having an at least partially annular shape are formed by an at least partially automated process.