Translating Die Apparatus for Complex Composite Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Uncured composite materials can suffer from material trapping and induced tension between forming dies, leading to potential damage due to insufficient tensile strength and fiber distortion when forming complex shapes.
Innovation Solution
A translating die apparatus with movable and fixed dies, where the movable dies translate simultaneously with the actuation of the mounts, allowing for the formation of complex shapes without stretching the material, and incorporating features like indexing and control systems for precise movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional forming dies are used to form complex shapes, then the material can be shaped, but tension is induced in the material causing fiber distortion and damage
Solution Approach 1:
The patent applies the dynamics principle by making the lower die movable relative to the upper die. The lower die translates horizontally along with the material during forming, dynamically adjusting its position to maintain material contact while reducing tension. This dynamic movement allows the die to follow the material's deformation, preventing the material from being stretched excessively and avoiding fiber distortion in composite materials.
Solution Approach 2:
The movable lower die acts as an intermediary element between the fixed upper die and the material. Instead of directly applying compressive force that would induce tension, the lower die mediates the forming process by translating with the material, distributing forces more evenly and preventing harmful tension buildup while still achieving the desired complex shape.
2Productivity
If the dies are moved toward each other to form the material, then the material is formed, but material becomes trapped between the dies causing induced tension
Solution Approach 1:
The lower die is designed to move dynamically in the horizontal direction during the forming process, translating along with the material as it deforms. This dynamic movement prevents material from becoming trapped between the dies by maintaining continuous contact and accommodating material flow, thereby eliminating the harmful tension that would otherwise be induced by static die configurations.
3Shape
If uncured composite material is subjected to external loads during forming, then the material can be shaped, but fiber distortion occurs due to insufficient tensile strength
Solution Approach 1:
The movable lower die translates horizontally during forming, dynamically adapting to the material's deformation. This dynamic adjustment allows the die to follow the material's flow without imposing excessive external loads, thereby maintaining fiber alignment and preventing distortion while still achieving the desired formed shape.
Solution Approach 2:
The patent changes the operational parameters of the forming process by introducing horizontal translation of the lower die. This parameter change modifies the stress state during forming, reducing tensile loads on the material and preventing fiber distortion while maintaining the ability to achieve complex formed shapes.
Data Source
AI summary
A translating die apparatus and method for forming a piece of material into a part having complex contours. The translating die apparatus may comprise upper and lower mounts, fixed upper and lower dies fixed to the upper and lower mounts, respectively, and movable upper and lower dies translatably coupled with the mounts and configured to translate laterally toward and away from the fixed upper and lower dies. The piece of material may be placed between the upper and lower dies and one of the mounts may be actuated toward another of the mounts to sandwich the piece of material between the upper and lower dies. Simultaneously, the movable upper and lower dies may translate toward the fixed upper and lower dies, until the movable and fixed dies abut each other when the upper and lower dies are fully pressing the piece of material therebetween.