Pre-cured Doubler Integration for Aircraft Composite Shell Manufacturing
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Solution Overview
Problem
The production of shell-shaped components with local reinforcing zones and stiffening elements is complicated by the integration of internal and external doublers, which affects aerodynamics and requires significant manufacturing adjustments.
Innovation Solution
A process involving the arrangement of pre-cured doublers and stiffening elements on a partially cured shell skin, with pre-cured connecting angles, allowing for separate manufacturing and precise machining, and curing under controlled conditions to form a shell-shaped component with improved mechanical properties and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If internal doublers are applied to the inner side of the component, then the structural reinforcement is achieved, but the manufacturing complexity and integration difficulty increase significantly
Solution Approach 1:
The doubler is pre-formed and cured separately before being integrated into the shell structure. This preliminary preparation allows the doubler to be manufactured with precise tolerances and then simply positioned and cured in place, avoiding the complexity of integrating internal doublers during the main manufacturing process
Solution Approach 2:
The doubler is manufactured as a separate, independent component rather than being integrated into the main shell structure during forming. This segmentation allows for specialized manufacturing of the doubler and simplifies the overall assembly process
2Ease of manufacture
If external doublers are placed on the outer side of the component, then the inner structure is not adversely affected, but the aerodynamic contour is compromised
Solution Approach 1:
The doubler is designed to match the local contour requirements at specific reinforcement locations. By forming the doubler to the precise local geometry needed, the aerodynamic contour is maintained while still providing the necessary structural reinforcement at that specific location
3Productivity
If the doubler is integrated into the manufacturing means, then the component is produced in one cycle, but any change to the doubler requires adjustment to the manufacturing means
Solution Approach 1:
The doubler is pre-formed and cured as a separate component before integration into the shell structure. This preliminary preparation allows the doubler to be manufactured with precise tolerances and then simply positioned and cured in place, avoiding the complexity of integrating internal doublers during the main manufacturing process
Solution Approach 2:
The separate doubler component can be used with different shell configurations and manufacturing setups. The universal doubler design allows it to be applied to various shell geometries without requiring custom tooling for each configuration
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 process simplifies the production of complex shell-shaped components with enhanced mechanical properties and flexibility, reducing manufacturing risks and maintaining aerodynamic integrity by allowing for precise control over doubler geometry and material selection.
Implementation Method 1
The resin system used is preferably a curable resin system, in particular a two-component polyurethane system or a two-component polyester system, but也可以是 epoxy resin systems, vinyl ester resin systems or the like
Data Source
AI summary
Disclosed is a process for producing a substantially shell-shaped component, from substantially carbon-fiber-reinforced synthetic material having at least one local reinforcing zone and at least one stiffening element, in particular a fuselage shell, a wing shell, a vertical stabilizer shell or horizontal stabilizer shell of an aircraft or the like. The process according to the invention comprises the following steps:arranging at least one doubler which has already been cured, on an at most partially cured shell skin to form the local reinforcing zone,applying at least one stiffening element which has already been cured, andplacing at least one at most partially cured connecting angle bracket against the at least one stiffening element at least in the region of the at least one doubler, andcuring the shell skin and the connecting angle bracket.