Rotatable Tray Drape Forming Apparatus for Composite Flange Wrinkle Control
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Solution Overview
Problem
Uncontrolled compression during hot drape forming of composite materials often results in buckling or wrinkling of plies, leading to defects in composite parts, particularly in aerospace applications where precise shaping is critical.
Innovation Solution
A drape forming apparatus with a pressurized bladder and a rotatable tray system, where a resistance device controls the rate of rotation to apply uniform pressure, preventing wrinkles and ensuring consistent formation of composite structures with flange portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If composite material is forced around a mandrel with vacuum bag or pressurized bladder, then composite parts can be formed for aerospace applications, but uncontrolled compression results in buckling or wrinkling of plies
Solution Approach 1:
The tray is made rotatable about a pivot line, transforming from a static to a dynamic system. This allows the tray to rotate during the forming process, enabling controlled material flow and pressure distribution that prevents buckling and wrinkling while maintaining manufacturing efficiency
Solution Approach 2:
The resistance device dynamically adjusts the rate of rotation of the tray, changing the temporal parameter of the forming process. By controlling rotation speed, the system optimizes both material formation quality and defect prevention, resolving the contradiction between ease of manufacture and manufacturing precision
2Shape
If pressurized bladder applies force to form composite structure, then shaping is achieved, but uncontrolled compression causes defects in flange portions
Solution Approach 1:
The rotatable tray introduces dynamic motion to the forming process. As the tray rotates at a controlled rate, it distributes the compressive force from the pressurized bladder more evenly across the flange portion, preventing localized over-compression that causes defects while maintaining the desired shape
Solution Approach 2:
The resistance device provides feedback control by adjusting the rotation rate based on the forming process requirements. This closed-loop control ensures that pressure is applied at the optimal rate, maintaining both shape accuracy and reliability by preventing defect formation
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 system enables more reliable, defect-reduced, and uniform formation of composite structures by controlling pressure and rotation, enhancing the quality of composite parts in aerospace and other applications.
Implementation Method 1
The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line
Implementation Method 2
a resistance device coupled to said tray, said resistance device configured to provide a second force that opposes the first force to control a rate of rotation of said tray
Implementation Method 3
heating one or more plies of flat pre-impregnated (i.e., prepreg) composite material, and forcing the composite material around a mandrel
Data Source
Figure 1
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AI summary
A drape forming apparatus (202) for use in forming a composite structure is provided. The apparatus includes a forming tool (212) including an upper forming surface (214) and at least one side forming surface (216) that extends from the upper forming surface. The forming tool is configured to receive at least one layer (218) of composite material extending over the upper forming surface. The apparatus also includes a flange forming device (200, 228, 238, 244, 248) including a tray (206, 230, 240) coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion (222) of the at least one layer of composite material. A pressurized bladder (226) extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line (208), and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.