Segmented Mandrel Tool for Large Composite Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fabricating and curing large composite structures, such as aircraft fuselages, are inefficient and costly, either requiring sequential fabrication and curing of parts or the use of large tools that must be disassembled, which is time-consuming and complex.
Innovation Solution
A system and method that involves using a tool with removably attached mandrel segments to support and cure composite parts, allowing them to be cut into segments for removal without disassembling the tool, and then reassembled off the tool to form the large composite structure, utilizing automated fiber placement, curing mechanisms, and reassembly mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large tool is used to fabricate and cure a single-piece large composite structure, then the structure can be fabricated as a single piece, but the tool must be disassembled into small subcomponents for removal which is time-consuming and inefficient
Solution Approach 1:
The tool is divided into multiple modular segments that can be independently removed after curing. Each segment can be detached without disassembling the entire tool, allowing rapid tool reconfiguration while maintaining the capability to fabricate large single-piece structures.
Solution Approach 2:
The tool incorporates movable and reconfigurable components that allow it to adapt between different fabrication modes. The tool can transition from a unified large structure support to a segmented configuration for efficient removal, and can be reconfigured for subsequent fabrication cycles.
2Productivity
If multiple independent part segments are fabricated and cured on different supportive tools, then the fabrication process can be parallelized, but multiple fabrication machines must be provided and maintained which is costly
Solution Approach 1:
A single large-capacity tool can accommodate multiple part segments simultaneously through its modular segmented design. The tool functions as both a unified support structure and as multiple independent fabrication stations, eliminating the need for multiple separate machines while maintaining parallel fabrication capability.
Solution Approach 2:
Multiple fabrication capabilities are merged into one unified tool system. The tool can support and cure multiple part segments in different configurations, combining the functions of what would traditionally require separate machines into a single multi-functional platform.
3Ease of operation
If the tool is designed with mandrel segments that can be removed without disassembly, then the removal process is simplified, but the tool design becomes more complex
Solution Approach 1:
The tool is designed with pre-segmented mandrel sections that are independently removable. Each segment is designed as a discrete unit with standardized connection interfaces, allowing simple attachment and detachment without requiring complex disassembly procedures.
Solution Approach 2:
The tool is pre-configured with segmentation features and connection mechanisms during its design phase. The mandrel segments are prepared in advance with standardized interfaces, so that during operation, removal and reconfiguration can be performed simply without ad-hoc complex procedures.
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 enables efficient fabrication and curing of large composite parts without the need for disassembling tools, reducing costs and time, and allows for the formation of complex structures like aircraft fuselages with improved thermal management and structural features.
Implementation Method 1
The automated fiber placement machine may be configured to apply composite material comprising resin and synthetic fibers onto the mandrel segments to fabricate the large composite part as a single piece on the tool
Implementation Method 2
The curing mechanism may be configured to cure the composite material on the mandrel segments to cure the large composite part on the tool
Data Source
AI summary
A system and method for fabricating large composite fuselages or other vehicle structures, in which the composite structure is fabricated and cured as on a tool, segmented and removed from the tool without disassembling the tool, and then reassembled off the tool to reform the large structure. The tool includes mandrel segments attached to a substructure. The attachments may be moveable to accommodate differential expansion and contraction during curing, and the tool may be rotatable to facilitate access. A composite material of resin and synthetic fibers is applied over the mandrel segments to fabricate the structure on the tool. Caul plates are secured over the composite material, and the composite material is cured on the tool. The resulting structure is cut into part segments which are then removed from the tool, and the part segments are joined to reassemble the large composite structure off the tool.