Segmented Mandrel Extraction for Twisted Hollow CMC Airfoils
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Solution Overview
Problem
Existing mandrel extraction methods for twisted and/or curved composite parts, such as CMC airfoils, are challenging due to interference with the development of the CMC part during thermal treatment and are often not reusable, leading to increased costs and waste.
Innovation Solution
A segmented mandrel system with aligned recesses and protrusions allows for the extraction of mandrel segments from highly twisted and/or curved parts by using an extraction tool that engages with keyways and gaps, enabling reusable mandrel segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a mandrel is used to form twisted and/or curved CMC airfoil parts, then the aerodynamic shape requirements are met, but the mandrel becomes difficult or impossible to extract
Solution Approach 1:
The mandrel is divided into multiple segments that can be extracted individually from the CMC airfoil part. Each segment is separated by gaps, allowing extraction tools to access and remove them one at a time without interfering with the aerodynamic shape of the final part.
Solution Approach 2:
The mandrel segments are designed to be extractable from the formed part through keyways and gaps. Extraction tools can be inserted through these openings to remove the mandrel segments, solving the extraction difficulty while maintaining the twisted and curved airfoil shape.
2Ease of operation
If mandrel materials are used that are substantially absorbed during thermal treatment, then the mandrel can be removed from the CMC part, but the fugitive material interferes with CMC development, increases densification time, and contaminates the desired material
Solution Approach 1:
Instead of using mandrel materials that are absorbed or degraded during thermal treatment, this invention uses mandrel segments that are physically extracted from the CMC part through mechanical means. The segments are removed through keyways and gaps using extraction tools, avoiding contamination of the CMC material while maintaining easy removal.
Solution Approach 2:
The mandrel segments serve as a temporary form that is completely removed after shaping the CMC part. The design includes features like keyways and gaps that facilitate the removal of these intermediary elements without leaving residues that would interfere with CMC development or contaminate the final product.
3Shape
If a mandrel is used for twisted and/or curved parts, then the complex aerodynamic shape is achieved, but the mandrel is not reusable, leading to waste and increased cost
Solution Approach 1:
The mandrel is segmented into multiple removable sections that can be extracted from the CMC part and reused for future manufacturing. The gaps between segments and the keyway designs enable easy removal and storage of segments for subsequent use, eliminating waste and reducing costs.
Solution Approach 2:
The mandrel segments are designed to be completely removed from the CMC part after serving their shaping function. The extraction features allow these segments to be recovered and reused in future airfoil manufacturing, preventing material waste and reducing overall production costs.
Data Source
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AI summary
Systems and methods are disclosed for producing a hollow composite part, such as a CMC airfoil, using a segmented mandrel formed of individual mandrel segments. The individual mandrel segments may be dimensioned to permit extraction from highly twisted and/or curved parts. There is provided a system for producing a curved and/or twisted hollow composite part (100), comprising a first segment (20) of cavity mandrel (200) configured for a first portion of the composite part (100), the first segment (20) having a first opening (210) extending therethrough; and a second segment (20) of cavity mandrel (200) configured for a second portion of the composite part (100), the second segment having a second opening (210) extending therethrough that is substantially aligned with the first opening (210), wherein the second segment (20) is disposed adjacent to the first segment (20).