Composite Part Thickness Transition via Stepped Ply Segmentation
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Solution Overview
Problem
Aircraft composite material parts with large variations in thickness pose challenges for manufacturing using Automatic Tape Lay-Up (ATL) machines, as they require extensive and weight-increasing thickness changing ramps, especially for pronounced differences.
Innovation Solution
A stack structure with a transition zone featuring continuous plies and stepped plies to compensate for thickness differences, allowing for a single-part manufacturing with optimized weight and dimensions, using ATL machines by structuring the stack with outer and central sections and intermediate sections that terminate in a stepped manner in the transition zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ATL machines are used to manufacture composite parts with large thickness variations, then manufacturing efficiency is improved, but the transition zone length increases greatly leading to weight increase
Solution Approach 1:
The stack is segmented into different types of plies (continuous plies and stepped plies) that perform different functions. Continuous plies maintain structural integrity across the transition zone, while stepped plies create the thickness variation. This segmentation allows the transition zone to be shorter without compromising manufacturing capability or part strength.
Solution Approach 2:
Different zones of the stack are given different qualities: continuous plies are used in zones requiring structural continuity, while stepped plies are used in zones requiring thickness variation. This local differentiation allows the transition zone to be optimized for both manufacturing and weight reduction simultaneously.
2Weight of moving object
If the transition zone length is reduced to decrease weight, then weight is optimized, but manufacturing complexity increases for ATL machines
Solution Approach 1:
The stack structure is divided into continuous plies and stepped plies with distinct functions. This segmentation simplifies the manufacturing process by clearly defining which plies should extend through the transition zone and which should terminate, making the complex stack structure manageable for ATL machines.
Solution Approach 2:
The stacking tool is designed with a ramp that pre-defines the transition zone geometry before manufacturing. This preliminary action guides the ATL machine to automatically create the correct stack structure, reducing the complexity of real-time manufacturing decisions and enabling shorter transition zones.
3Ease of manufacture
If thickness changing ramps are extended to accommodate ATL machine limitations, then manufacturing feasibility is maintained, but dimensions and weight increase
Solution Approach 1:
The stacking tool incorporates a pre-designed ramp structure that prepares the transition zone geometry in advance. This preliminary action allows ATL machines to manufacture shorter transition zones by following the pre-defined path, maintaining manufacturing feasibility while reducing the transition zone length from what would otherwise be required.
Solution Approach 2:
The stacking tool ramp acts as an intermediary between the ATL machine and the final part geometry. It mediates the manufacturing process by providing a physical guide that enables the ATL machine to create complex thickness variations within shorter distances, thus reducing the transition zone length while maintaining ease of manufacture.
Data Source
AI summary
A composite material part and method for manufacturing the part. The part has a large variation in thickness between a first zone having a thickness E1 and a second zone having a thickness E2, which is made as a single part with a transition zone, external surfaces of which have gradients of magnitude, in which the structure of the stack includes; b1) a plurality of continuous plies that extend in the three zones; b2) a plurality of plies that extend in the first zone and in the transition zone, terminating in a stepped manner in the transition zone; b3) a plurality of plies that extend in the first zone and in the transition zone, terminating in a stepped manner in the transition zone.