Reconfigurable Die Forming Contoured Composite Parts
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Solution Overview
Problem
Current methods for forming highly contoured composite structural members are limited by wrinkling issues and require labor-intensive hand lay-up techniques, as well as inflexible tooling that necessitates separate dies for varying part shapes, making it costly and inefficient to produce parts with complex contours.
Innovation Solution
A method and apparatus using reconfigurable mating dies with independently controllable die portions that maintain tension on the composite charge, allowing for the formation of complex contours without wrinkling, and enabling the same dies to support and transport the formed parts, eliminating the need for special tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional flat multiply charge is formed using conventional dies, then the part shape is limited to straight or mildly contoured shapes, but highly contoured structural members cannot be formed due to ply wrinkling
Solution Approach 1:
The die is made dynamically controllable with independently adjustable die portions that can be positioned at different heights. This dynamic adjustment capability allows the die to adapt to highly contoured shapes while maintaining proper ply tension and preventing wrinkling during the forming process.
Solution Approach 2:
The die is segmented into multiple independently controllable portions or zones. Each segment can be adjusted individually to match the specific contour requirements at different locations, enabling complex 3D shaping while maintaining control over ply formation and preventing wrinkles.
2Manufacturing precision
If hand lay-up techniques are used to form highly contoured parts, then wrinkling is reduced, but the process becomes labor intensive and costly
Solution Approach 1:
The apparatus enables automated forming where the programmably controllable die automatically positions and forms the plies according to pre-programmed sequences. This eliminates the need for manual hand lay-up operations while maintaining wrinkle-free formation, thereby increasing productivity and reducing labor costs.
Solution Approach 2:
Manual mechanical hand lay-up operations are replaced with an automated programmable forming system. The computer-controlled die portions automatically perform the forming actions that previously required skilled manual labor, achieving both high precision and high productivity.
3Ease of manufacture
If permanent shape dies are used for forming, then the tooling is simple, but separate tooling dies must be fabricated for differing part shapes
Solution Approach 1:
The die transitions from a static permanent shape tooling to a dynamic programmably controllable tooling. The die portions can be repositioned and reconfigured through programming to accommodate different part shapes, eliminating the need for multiple separate tooling dies while maintaining ease of operation.
Solution Approach 2:
The die is designed with universal adaptability to form multiple different part shapes using the same tooling. By programming the independently controllable die portions to different configurations, a single die can produce various contoured shapes, replacing the need for multiple dedicated tooling dies.
4Device complexity
If conventional forming presses are used, then the equipment is simple, but separate fixtures are required for forming, transporting and installing formed parts
Solution Approach 1:
The apparatus merges multiple functions into a single integrated system. The programmably controllable die serves both as the forming tool and as a support fixture for the formed part. This consolidation eliminates the need for separate forming presses and transport fixtures, reducing overall device complexity while improving productivity through process integration.
Solution Approach 2:
The die performs multiple functions: it forms the highly contoured part shape, supports the formed part during the process, and can be reconfigured for different part types. This multi-functionality eliminates the need for separate specialized fixtures for forming, transporting, and installing parts.
Data Source
AI summary
A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.