Segmented Mandrel Tool for Composite Fuselage Fabrication
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Solution Overview
Problem
The fabrication and curing of large composite structures, such as aircraft fuselages, are inefficient due to the need for either sequential fabrication and curing of parts or the use of costly and time-consuming disassembly of large tools, which complicates the assembly and disassembly processes.
Innovation Solution
A system and method that involves fabricating and curing a large composite part on a tool with removably attached mandrel segments, allowing the part to be segmented and removed without disassembling the tool, and then reassembled off the tool using an automated fiber placement machine, curing mechanism, and reassembly mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large composite structure is fabricated as a single piece on a large tool, then manufacturing precision is improved, but device complexity and loss of time increase due to the need to disassemble and reassemble the tool
Solution Approach 1:
The tool is divided into multiple tool segments that can be independently removed and repositioned. This allows the composite structure to be fabricated as a single piece on the complete tool, then the tool segments are removed (not disassembled) to facilitate part removal, and the structure can be segmented and reassembled without reassembling the tool itself.
Solution Approach 2:
Instead of disassembling the tool to remove the composite part, the invention inverts the approach by keeping the tool assembled and removing the tool segments around the part. The part is removed through the space created by removing tool segments, eliminating the time-consuming tool disassembly and reassembly process.
2Ease of operation
If the tool is disassembled into small subcomponents for part removal, then ease of operation is improved, but device complexity and loss of time worsen due to the number of components to assemble and disassemble
Solution Approach 1:
The tool is segmented into multiple removable tool segments that can be independently taken off the composite structure. Each segment can be removed and repositioned without affecting the others, simplifying the removal process while maintaining tool integrity when assembled.
Solution Approach 2:
The tool transitions from a static, fixed structure to a dynamic, reconfigurable system where segments can be removed and repositioned as needed. This allows the tool to adapt its configuration based on the fabrication and removal requirements of different composite parts.
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 by allowing them to be segmented and reassembled without disassembling the tool, reducing costs and time, while maintaining structural integrity and precision.
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.