Preform Tensioning on Inner Mold Lines to Prevent Wrinkling
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Solution Overview
Problem
Existing methods for forming preforms into shaped bodies, particularly in aerospace applications, face issues with wrinkling and kinking due to uneven tension during the shaping process, which affect mechanical properties and reproducibility.
Innovation Solution
The use of floating grip plates coupled to a male inner mold line (IML) tool, equipped with adjustable tensioning systems, such as gear rack-based or screw-based mechanisms, to apply even tension to the preform, reducing or eliminating wrinkling and kinking by allowing controlled translation and precise tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming methods are used to form preforms into shaped bodies, then the shaping process can be completed, but wrinkling and kinking occur due to uneven tension
Solution Approach 1:
The tensioning system is divided into multiple independent tensioning points distributed along the preform. Each tensioning point can apply force independently, allowing localized adjustment of tension to prevent wrinkling and kinking in different regions of the shaped body during forming.
Solution Approach 2:
The tensioning force is distributed non-uniformly across different regions of the preform based on local requirements. Areas prone to wrinkling receive higher tension while other areas receive appropriate tension levels, creating locally optimized stress distribution to maintain surface quality and mechanical properties.
2Manufacturing precision
If fixed tensioning is applied during preform forming, then the process is simple, but uneven tension causes wrinkling and kinking
Solution Approach 1:
The tensioning system transitions from fixed to dynamic adjustment capability. The tensioning elements can be adjusted during the forming process to maintain uniform tension distribution, allowing the system to adapt to changing geometric conditions as the preform is formed into the shaped body.
Solution Approach 2:
The tensioning parameters (force magnitude and distribution) are adjusted during the forming process to maintain uniform tension. By changing these parameters dynamically, the system achieves uniform tension distribution without requiring an overly complex mechanical structure.
3Reliability
If traditional forming tools are used, then the equipment is simple, but the mechanical properties and reproducibility of shaped bodies are affected
Solution Approach 1:
The forming tool incorporates multiple segmented tensioning points that can be independently adjusted. This segmentation allows precise control of tension at different locations, ensuring consistent mechanical properties and high reproducibility across multiple forming operations, justifying the increased structural complexity.
Solution Approach 2:
The forming tool enables dynamic adjustment of tension parameters during the forming process. This capability ensures that optimal tension conditions are maintained throughout forming, producing shaped bodies with consistent mechanical properties and high reproducibility, while the adjustable mechanism adds necessary complexity to the tool structure.
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
The method ensures even tension distribution, reducing or eliminating undesired wrinkling and kinking, thereby improving the mechanical properties and reproducibility of the shaped bodies.
Implementation Method 1
threads on a gear of the tensioning mechanism interact with threads on the gear rack to translate the gear rack in a translation direction
Implementation Method 2
threads on the outer surface of the lead screw interact with threads on an inner surface of the lead nut to translate the lead nut in a translation direction
Implementation Method 3
the ball bearing assembly holds the threaded stud knob and the gear in place with respect to the surface of the inner mold line
Data Source
AI summary
A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is pressed into a grip strip coupled to a side of the inner mold line. The grip strip is translated in a first direction to tension the preform into a shaped body.