Releasable Forming Element for Composite Stiffener Precision
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Solution Overview
Problem
The production of fiber composite components for the aerospace industry is time-consuming and expensive due to the need for multiple tools and processes in developing and manufacturing stringer-reinforced panels, which requires frequent adjustments to tools and materials.
Innovation Solution
A forming tool with a mold section and a releasable forming/supporting element that shapes and supports the stiffening section, allowing it to be used simultaneously in the HotForm process and subsequent hardening, reducing the need for separate tools and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate tools are used for HotForm process and setting/hardening process, then manufacturing precision can be maintained, but device complexity and production time increase significantly
Solution Approach 1:
The patent combines the forming tool and setting tool into a single integrated tool. The forming section with mold section and forming/supporting element is designed to perform both the HotForm shaping process and the subsequent setting/hardening process in one tool, eliminating the need for separate tools and reducing production time while maintaining precision.
Solution Approach 2:
The forming section is designed as a multi-functional component that serves dual purposes: first as the forming tool during HotForm process, and then as the setting tool during hardening process. The mold section and forming/supporting element are configured to maintain geometric precision throughout both process stages without requiring tool changes.
2Manufacturing precision
If expensive tool materials are used, then manufacturing precision and reliability are improved, but production cost increases
Solution Approach 1:
The patent employs inexpensive materials such as steel or wood for the forming tool and forming/supporting element. These cheaper materials are sufficient for the application, eliminating the need for expensive specialized tool materials while maintaining adequate manufacturing precision and reliability for producing the stiffening section.
3Manufacturing precision
If multiple adjustment steps are performed, then manufacturing precision can be optimized, but loss of time and production efficiency decrease
Solution Approach 1:
The forming section is pre-configured with the correct geometry and dimensions during manufacturing. The mold section and forming/supporting element are designed in advance to accommodate the required laminate thicknesses and geometric features, eliminating the need for time-consuming adjustments during production. Any necessary adjustments can be made by simply changing the semi-finished fiber product rather than modifying the tool.
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 saves time and money by allowing the same forming/supporting element to be used in both shaping and hardening processes, reducing the requirement for expensive tool materials and minimizing adjustments, while enabling the use of inexpensive materials like steel or wood for the forming tool.
Implementation Method 1
A shaping/supporting element (4) is shaped by means of the shaped section (3) of the forming tool (2)
Implementation Method 2
The stiffening section (7, 8, 9) formed is positioned in a defined manner relative to an associated fiber composite component section (12), being supported by the forming/supporting element (4). The stiffening section (7, 8, 9) is then cured to form the reinforced fiber composite component (1).
Data Source
Figure 1a~2b
Figure 3~4
Figure 5~6
AI summary
In a method for producing a reinforced composite fibre component (1) for air and space travel, a shaping tool (2) with a predetermined shaping section (3) is provided. A shaping/supporting element (4) is shaped by means of the shaping section (3) of the shaping tool (2). A semi-finished fibre product (5) is then deposited at least in some sections on the shaped shaping/supporting element (4). The shaping/supporting element (4) is used to shape the deposited semi-finished fibre product (5) in order to form at least one reinforcing section (7, 8, 9). The shaping/supporting element (4) together with the reinforcing section (7, 8, 9) formed thereon is removed from the shaping tool (2), after which the reinforcing section (7, 8, 9) formed is positioned in a defined manner relative to an associated composite fibre component section (12) by means of support by the shaping/supporting element (4). The reinforcing section (7, 8, 9) is cured in order to form the reinforced composite fibre component (1). A shaping device is provided with a predetermined shaping section (3) for the releasable receiving of a shaping/supporting element (4).