Composite Blade Stringer Tooling Without Tool Transfer
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Solution Overview
Problem
Current manufacturing processes for composite structures involve multiple tools for forming and curing, leading to increased manufacturing time, tool investment cost, storage space requirements, and potential inconsistencies due to material transfer between tools.
Innovation Solution
A forming and curing tool that integrates both forming and curing functions, using a first and second die with forming surfaces, a tool lid to create a curing chamber, and a press to hold and move these components, allowing simultaneous forming and curing of composite blade stringers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple tools are used for forming and curing, then specialized forming and curing functions can be achieved, but manufacturing time increases and tool investment cost increases
Solution Approach 1:
The patent combines forming and curing tools into a single integrated tool assembly. The forming tool includes a forming cavity and curing cavity that can accommodate workpieces in the same tool, eliminating the need to transfer between separate forming and curing tools. This merging reduces manufacturing time while maintaining specialized forming and curing functions through properly configured cavity structures and heating/pressing mechanisms.
2Reliability
If multiple tools are used for forming and curing, then specialized forming and curing functions can be achieved, but tool investment cost increases
Solution Approach 1:
The forming tool is designed with multi-functionality to perform both forming and curing operations. The tool includes a forming cavity with forming plates for shaping the workpiece and a curing cavity with heating elements and pressing mechanisms for curing. This universal tool design eliminates the need for separate forming and curing tools, reducing tool investment cost while maintaining specialized functions through integrated design.
3Reliability
If multiple tools are used for forming and curing, then specialized forming and curing functions can be achieved, but storage space requirements increase
Solution Approach 1:
By merging forming and curing functions into a single tool assembly, the patent reduces the total number of tools required. The integrated tool occupies less storage space compared to having separate forming and curing tools, while maintaining specialized forming and curing capabilities through properly configured cavity structures and heating/pressing mechanisms within the same tool.
4Ease of manufacture
If material is transferred between tools, then forming and curing can be performed separately, but manufacturing precision decreases due to potential inconsistencies
Solution Approach 1:
The patent eliminates material transfer between tools by integrating forming and curing operations within the same tool assembly. The workpiece remains in the forming cavity throughout the forming and curing processes, eliminating potential inconsistencies introduced by transfer operations. The forming cavity and curing cavity are designed to maintain proper positioning and alignment, ensuring manufacturing precision while allowing separate forming and curing functions.
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 integrated approach reduces manufacturing time, minimizes tool count and storage needs, and enhances consistency by eliminating material transfer-related issues, while maintaining precise control over heat and pressure application.
Implementation Method 1
a first die with a heating system and a first forming surface
Implementation Method 2
a press configured to hold and move the first die, the second die, and the tool lid relative to each other
Implementation Method 3
a first die with a number of vacuum paths through the first die
Data Source
AI summary
A first cut and kitted material is held against a first flange face of a first die. A second cut and kitted material is held against a second flange face of a second die. The method simultaneously forms the first cut and kitted material against a first blade face of the first die and the second cut and kitted material against a second blade face of the second die. The first cut and kitted material and the second cut and kitted material are clamped between the first die and the second die after forming the first cut and kitted material and the second cut and kitted material. A composite stringer preform comprising the first cut and kitted material, the second cut and kitted material, a noodle, and a base material is cured while the composite stringer preform is against the first forming surface and the second forming surface.