초록 ▼

A tooling concept uses a compliant forming surface for forming composite parts. The tooling concept utilizes a rigid support substructure that has a thin compliant forming surface. In the preferred embodiment of the invention, the tooling concept is used to form a composite sine wave spar. A preferr

A tooling concept uses a compliant forming surface for forming composite parts. The tooling concept utilizes a rigid support substructure that has a thin compliant forming surface. In the preferred embodiment of the invention, the tooling concept is used to form a composite sine wave spar. A preferred embodiment of the tooling concept includes upper and lower tool inserts and side tool inserts. The upper tool insert has a compliant forming surface that is located in between a rigid support substructure and the composite material used to form the composite part. Composite prepreg is laid up over a sine wave contour on the upper and lower tool inserts to form upper and lower U-shaped composite workpieces. The upper and lower tool inserts and workpieces are then brought together to form a sine wave I-beam. Radius fillers are then applied to the intersections between the upper and lower composite workpieces and cap strips are placed over the flanges of the joined composite workpieces. Side tools and end tools are then placed around the joined upper and lower tool inserts. The resulting assembly is covered with a breather cloth, baked in a vacuum bag and cured in an autoclave. During curing, the autoclave applies a hydrostatic pressure on the upper tool insert and thus compliant forming surface. The compliant forming surface in turn applies a consolidation and forming pressure to the composite workpiece within the tools. During curing, the compliant forming surface deforms slightly to account for thickness variations in the composite workpiece in order to produce a better quality formed composite part.

대표청구항 ▼

[ The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:] [1.] A tooling system for forming a composite part, comprising:an elastomeric, compliant covering seated on a rigid substructure and attached through retaining tabs projecting from the

[ The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:] [1.] A tooling system for forming a composite part, comprising:an elastomeric, compliant covering seated on a rigid substructure and attached through retaining tabs projecting from the covering, the tabs being received in corresponding recesses in the substructure, the covering including a forming surface; andat least one other tool to create a set of matched tooling, the other tool having a forming surface for complementary arrangement with the forming surface of the covering on the substructure so that the forming surfaces of the covering and tool define the geometry of the composite part, the forming surfaces being designed to apply a substantially constant consolidation pressure on the part during forming and curing, the covering on the complaint tool having a shrinkage of less than about 0.1% to hold dimensions of the part.