Thrust Reverser Cascade Molding Tooling
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Solution Overview
Problem
The existing methods for manufacturing air deflection cascades for aircraft thrust reverser systems using composite materials are costly and result in significant dimensional variability due to the use of numerous movable cores, leading to suboptimal aerodynamic performance.
Innovation Solution
A tooling system with molding bars and columns that allow for the simultaneous molding of vanes between spars, reducing the number of cores and operations, and enabling precise control over the geometry of the cascades through compression molding, thereby minimizing dimensional tolerances and enhancing aerodynamic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If numerous movable cores are used for molding cascades, then the cascade geometry can be formed, but the manufacturing cost increases and dimensional variability worsens
Solution Approach 1:
The patent merges multiple separate movable cores into a single monoblock molding core that can simultaneously form multiple vanes. This consolidation reduces the number of individual cores from several tens to just one, eliminating positioning tolerance accumulation between multiple cores while maintaining the ability to form complex cascade geometries with precise dimensional control.
Solution Approach 2:
The monoblock molding core is designed to perform multiple functions simultaneously - it can mold multiple rows of vanes in a single operation and can be reconfigured for different cascade geometries. This universal design eliminates the need for numerous specialized cores while maintaining geometric flexibility and precision.
2Shape
If numerous movable cores are used for molding cascades, then the cascade geometry can be formed, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate movable cores into a single monoblock molding core that can simultaneously form multiple vanes. This consolidation reduces the number of individual cores from several tens to just one, eliminating positioning tolerance accumulation between multiple cores while maintaining the ability to form complex cascade geometries with precise dimensional control.
Solution Approach 2:
The monoblock core contains multiple cavity copies that can simultaneously produce multiple identical or different vane geometries in one molding cycle. This copying capability maintains geometric complexity while reducing the number of physical cores needed, thereby lowering manufacturing costs.
3Productivity
If vanes are molded one by one using multiple cores, then each vane can be formed, but the number of operations increases and productivity decreases
Solution Approach 1:
The patent merges multiple separate movable cores into a single monoblock molding core that can simultaneously form multiple vanes in one operation. This eliminates the sequential molding process and reduces the total number of molding operations required, significantly improving productivity.
Solution Approach 2:
The monoblock core enables continuous molding of multiple vanes in a single operational cycle without the need to reposition or replace individual cores between operations. This continuous action eliminates idle time and operational interruptions, maximizing manufacturing efficiency.
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 simplifies the manufacturing process, reduces costs, and achieves cascades with geometries suited for improved aerodynamic performance by allowing all vanes to be made in one operation with reduced dimensional variability.
Implementation Method 1
a compression device for providing the displacement of the molding bar towards the molding column and the compression of elements made of a composite material arranged in the tooling and intended to form at least one part of the cascade to be manufactured
Data Source
AI summary
Tooling for manufacturing an air deflection cascade for a thrust reverser system of an aircraft nacelle includes a plurality of spars, each spar being connected to at least one adjacent spar by a plurality of deflection vanes. The tooling includes at least one molding bar and at least one molding column of a row of vanes, comprising two opposing lateral faces extending along the longitudinal direction of the tooling, and comprising molding cavities. The tooling includes a fixed structure on which the molding bar and the molding column are mounted. The fixed structure enabling a translational movement, along a transverse direction of the tooling, of the molding bar. The tooling includes a compression device to provide the compression of elements made of a composite material arranged in the tooling and intended to form at least one part of the cascade to be manufactured.