Shaping Tool with Curved Faces for Continuous Composite Forming
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Solution Overview
Problem
Current methods for manufacturing structural components for aircraft using fiber-reinforced composite materials are limited in their ability to produce complexly curved or twisted shapes in a continuous process, particularly for large-scale production with short production times.
Innovation Solution
A shaping tool and apparatus with curved and/or inclined shaping faces, comprising both rigid and elastically deformable materials, that can be adjusted to form semi-finished products containing reinforcing fibers into complex shapes, combined with a press and heating apparatus for continuous production, allowing for the creation of complexly curved or twisted components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional autoclave processes are used for manufacturing fiber-reinforced composite components, then complex shapes can be produced with high precision, but production time is long and large-scale continuous production is difficult
Solution Approach 1:
The shaping tool is divided into multiple shaping elements that can be independently adjusted, allowing different sections of the component to be formed simultaneously in a continuous process, thereby increasing production speed while maintaining precision
Solution Approach 2:
The fiber plies are pre-formed into a preliminary shape before final curing, allowing the continuous production process to maintain both high speed and precision by preparing components in stages
2Productivity
If continuous production methods are used for structural profiles with constant cross-section, then large numbers can be produced efficiently, but complexly curved or twisted shapes cannot be formed
Solution Approach 1:
The shaping tool incorporates adjustable and movable shaping elements that can dynamically adapt to different shape requirements, enabling the continuous production of both constant cross-section profiles and complexly curved or twisted shapes
Solution Approach 2:
The shaping tool allows modification of geometric parameters such as curvature and twist during the continuous forming process, enabling versatile production of different component shapes while maintaining high productivity
3Stability of the object's composition
If rigid shaping tools are used for forming fiber plies, then dimensional stability is achieved, but formability of complex shapes is limited
Solution Approach 1:
The shaping tool combines rigid structural elements for dimensional stability with elastically deformable shaping surfaces that can be adjusted to form complex shapes, achieving both stability and formability in a single integrated system
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
Enables the efficient and rapid production of complexly curved or twisted structural components for aircraft, such as frames and stringers, in large numbers, by allowing the semi-finished products to be shaped and cured in a continuous process, improving formability and reducing production time.
Implementation Method 1
at least one of the shaping-tool elements (48a, 48b) comprises an elastically deformable material
Implementation Method 2
heating apparatus (66) which is adapted to heat the semi-finished product (16) arranged between the first and second shaping-tool elements (48a, 48b)
Implementation Method 3
press (38) which is adapted to subject the semi-finished product (16), which is arranged between the first and second shaping-tool elements (48a, 48b), to force
Data Source
AI summary
A shaping tool for forming a semi-finished product which contains reinforcing fibers and is fed to the shaping tool in a continuous process comprises a first shaping-tool element and a second shaping-tool element which is located opposite the first shaping-tool element. The shaping-tool elements have shaping faces which face towards the semi-finished product, at least in certain operating phases of the shaping tool, and which are curved and/or inclined, at least in certain sections, in a direction of conveyance of the semi-finished product through the shaping tool, and/or curved and/or inclined, at least in certain sections, in a direction perpendicular to the direction of conveyance of the semi-finished product.