Composite Preform Tensioning Around Inner Mold Forming Beads
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Solution Overview
Problem
Current methods for forming shaped composite bodies, such as those used in aerospace applications, face challenges in applying appropriate tension to preforms to prevent wrinkling and kinking, especially when dealing with complex geometries and multiple planes, which affects the achievement of target mechanical properties and reproducibility.
Innovation Solution
The method involves using a male inner mold line tool with tensioning/forming beads and clamping assemblies, along with strapping mechanisms and forming rod assemblies, to incrementally tension and draw the preform into forming beads, ensuring controlled tensioning and stretching to conform to complex shapes while avoiding fiber wrinkling and kinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming methods are used to shape composite bodies, then the forming process can be completed, but wrinkling and kinking occur in the preform affecting mechanical properties
Solution Approach 1:
The forming system is segmented into multiple independent clamping assemblies distributed along the preform length, each capable of independent tensioning. This segmentation allows localized control of tension to prevent wrinkling in specific regions while maintaining overall form accuracy.
Solution Approach 2:
The clamping assemblies are designed with dynamic adjustment capabilities, allowing tension forces to be modified during the forming process. This dynamic control enables adaptation to varying curvature requirements along the preform, preventing both wrinkling and kinking through real-time tension optimization.
2Manufacturing precision
If high tension is applied to the preform to prevent wrinkling, then surface quality improves, but fiber kinking occurs due to excessive stress
Solution Approach 1:
Different clamping assemblies apply different tension levels tailored to local geometric requirements. Regions with higher curvature receive appropriate tension to prevent wrinkling, while sensitive areas use lower tension to avoid kinking, achieving surface quality without harmful stress concentrations.
Solution Approach 2:
The system dynamically adjusts tension parameters during forming based on real-time feedback and pre-programmed sequences. Tension magnitude and distribution are continuously optimized to maintain the preform in a safe stress range that prevents both wrinkling and kinking throughout the forming process.
3Manufacturing precision
If multiple clamping assemblies are used to control tension distribution, then wrinkling and kinking are reduced, but device complexity increases
Solution Approach 1:
Each clamping assembly is designed as a universal module capable of performing multiple functions: clamping the preform, applying tension, and providing positioning. This multi-functionality reduces the need for separate components and simplifies the overall system architecture despite using multiple assemblies.
Solution Approach 2:
The clamping assemblies incorporate self-adjusting mechanisms that automatically optimize tension distribution based on local preform geometry and forming stage. This self-service capability reduces the need for complex external control systems and manual intervention, simplifying operation despite the presence of multiple assemblies.
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 approach effectively reduces or eliminates wrinkling and kinking, allowing for the formation of shaped bodies with improved mechanical properties and reproducibility by providing controlled tensioning and stretching around complex radii and curvatures.
Implementation Method 1
each clamping assembly in the plurality of clamping assemblies includes a male member comprising a protrusion and a female member comprising a receptacle. In various embodiments, the male member and the female member, when coupled together, apply a clamping force to an end of the preform.
Implementation Method 2
incrementally tensioning the preform around a surface of an inner mold line using the plurality of clamping assemblies
Implementation Method 3
drawing the preform into a set of forming beads of the inner mold line
Data Source
AI summary
A manufacturing method is disclosed herein. The method includes arranging a preform with a plurality of clamping assemblies, the plurality of clamping assemblies disposed along ends of the preform; and forming the preform into a shaped body, the forming including: incrementally tensioning the preform around a surface of an inner mold line using the plurality of clamping assemblies; and drawing the preform into a set of forming beads of the inner mold line.