Tensioned Tooling Assembly for Wrinkle-Free Composite Forming
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Solution Overview
Problem
Existing tooling assemblies for stamp forming thermoplastic composite parts result in undesired wrinkling and material bulk during the formation of curved contours, leading to inefficiencies in the manufacturing process.
Innovation Solution
A tensioned tooling assembly with protruding portions that apply tension to the composite material, causing wrinkles to form in removable areas and eliminating them post-forming, while maintaining tension in the final part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nominal tooling assembly is used for stamp forming, then the forming process can be completed, but excess material bulk causes wrinkling and folding in the final part
Solution Approach 1:
The tooling assembly is segmented into multiple functional components: a bottom tool with protruding portions, a top tool with recessed portions, and a tensioning system. The protruding and recessed portions are distributed across the tooling surfaces to create localized tension zones that prevent wrinkle formation in critical areas while allowing controlled material flow.
Solution Approach 2:
The patent changes the geometric parameters of the tooling surfaces by adding protruding portions to the bottom tool and corresponding recessed portions to the top tool. These geometric modifications alter the material flow and tension distribution during forming, preventing excess material bulk from causing wrinkles in the final part.
2Manufacturing precision
If tensioning protruding portions are added to control wrinkle formation, then wrinkle control improves, but device complexity increases
Solution Approach 1:
The tooling assembly implements local quality by placing protruding portions only in specific locations on the bottom tool where wrinkle control is needed, with corresponding recessed portions on the top tool. This localized approach provides wrinkle control in critical areas without requiring complex modifications across the entire tooling assembly.
Solution Approach 2:
The protruding and recessed portions act as intermediaries between the forming force and the composite material. These features mediate the material flow and tension distribution, controlling wrinkle formation through their geometric interaction with the material rather than requiring complex active control systems.
3Shape
If the outer arc length is reduced during forming, then the curved contour is achieved, but excess material bulk is created
Solution Approach 1:
The tooling assembly is pre-configured with protruding and recessed portions before the forming process begins. These features are designed in advance to accommodate the reduction in outer arc length during forming, providing controlled material flow paths that minimize excess bulk while achieving the desired curved contour.
Solution Approach 2:
The patent addresses the material bulk problem by introducing vertical dimensionality through protruding and recessed portions. These features create three-dimensional tooling surfaces that control material distribution in the vertical direction, allowing the material to be redirected rather than simply compressed, thus reducing excess bulk while maintaining the curved contour.
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
The solution effectively controls and directs wrinkle formation, ensuring smooth, wrinkle-free final parts by removing excess material bulk, enhancing the manufacturing process efficiency.
Implementation Method 1
the plurality of tensioning protruding portions push first portions of the thermoplastic composite charge outwardly, causing wrinkles to form in the first portions which are removed after forming of a net part from the thermoplastic composite charge, and the plurality of tensioning protruding portions apply tension to second portions of the thermoplastic composite charge
Data Source
AI summary
There is provided a tensioned tooling assembly for a thermoplastic composite stamp forming process. The tensioned tooling assembly includes a bottom tool having a bottom tool outer flange with a bottom end, a bottom tool outer radius, and a bottom tool outer curved surface. The bottom tool includes a plurality of tensioning protruding portions spaced apart on, and outwardly extending from, the bottom tool outer curved surface. Each tensioning protruding portion defines an angle formed from the bottom tool outer radius to the bottom end. The tensioned tooling assembly further includes a top tool having a top tool outer flange with a bottom end, a top tool outer radius, and a top tool outer curved surface. The top tool includes a plurality of corresponding portions formed in, and spaced apart on, the top tool outer curved surface, the plurality of corresponding portions corresponding to the plurality of tensioning protruding portions.