US20100000667A1 - Moulding tool and method of manufacturing a part - Google Patents
Moulding tool and method of manufacturing a part Download PDFInfo
- Publication number
- US20100000667A1 US20100000667A1 US12/310,138 US31013807A US2010000667A1 US 20100000667 A1 US20100000667 A1 US 20100000667A1 US 31013807 A US31013807 A US 31013807A US 2010000667 A1 US2010000667 A1 US 2010000667A1
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- US
- United States
- Prior art keywords
- tool
- mandrel
- moulding
- mould line
- inner mould
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/30—Mounting, exchanging or centering
- B29C33/306—Exchangeable mould parts, e.g. cassette moulds, mould inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
- B29C33/485—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling cores or mandrels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
- B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
- B29L2031/3085—Wings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C3/00—Wings
- B64C3/18—Spars; Ribs; Stringers
- B64C3/182—Stringers, longerons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C3/00—Wings
- B64C3/18—Spars; Ribs; Stringers
- B64C3/187—Ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C3/00—Wings
- B64C3/24—Moulded or cast structures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
Abstract
A tool set comprising: a moulding tool comprising a moulding surface and a mandrel recess in the moulding surface; a first mandrel configured to fit into the mandrel recess and form a first component; and a second mandrel configured to fit into the mandrel recess and form a second component which has a different shape or size to the first component. A method of manufacturing a part, the method comprising: arranging a set of components on one or more inner mould line tools; forming a layer around the inner mould line tool(s); fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s); moulding the part by compressing the layer and the components between the inner and outer mould line tools; and removing the inner mould line tool(s) from the part.
Description
- The present invention relates in its various aspects to a moulding tool, a tool set, a method of manufacturing a moulding tool, and a method of manufacturing a part such as a composite part.
- U.S. Pat. No. 5,902,535 describes an inner mould line (IML) tool for resin film infusion moulding a component in a single-step moulding operation. The IML tool comprises a plurality of mandrels in a modular design. The mandrels may be individually assembled over a preform assembly, such that the surface configurations on the underside of the mandrels match with the stringers and intercostals of the preform assembly.
- A first aspect of the invention provides a moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, wherein the mandrel recess has a mandrel locator configured to engage with a mandrel so as to locate the mandrel at a desired position in the mandrel recess.
- Providing a mandrel recess in the moulding surface enables a mandrel to be fitted easily and accurately relative to the moulding surface.
- Typically the mandrel locator is configured to engage with the mandrel by means of a male/female connection (such as a hole or pin).
- A plurality of mandrel recesses may be formed in the moulding surface, which is typically a contiguous piece of material. Thus each mandrel recess can be used to receive a mandrel for a respective component such as a stringer, or an additional component such as a spar, rib foot or rib post.
- The tool may have only a single moulding surface on one side—for example for forming a half wing-box. Alternatively the tool may have a second moulding surface (either adjacent to or opposite to the first moulding surface); and one or more mandrel recesses in the second moulding surface, each configured to receive a respective mandrel. In this case the tool can be used to form a tubular part such as a full wing-box.
- Typically each recess has been formed by removing material from the moulding tool—for instance by machining from a billet.
- A further aspect of the invention provides a tool set comprising:
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- a moulding tool according to the first aspect of the invention;
- a first mandrel configured to fit into the mandrel recess and form a first component; and
- a second mandrel configured to fit into the mandrel recess and form a second component which has a different shape or size to the first component.
- Thus the tool can be used in a modular tool set, in which a variety of mandrels can be interchangeably fitted into the mandrel recess(es) to form a desired component.
- A further aspect of the invention provides a tool set comprising:
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- a moulding tool according to the first aspect of the invention;
- two or more stringer mandrels each configured to fit into a respective one of the stringer mandrel recesses and form a respective stringer; and
- one or more additional mandrels each configured to fit into a respective one of the additional mandrel recesses and form a respective additional component.
- Thus the moulding tool can accommodate mandrels for stringers and also for additional components such as rib feet, spars and/or rib posts.
- A further aspect of the invention provides a method of manufacturing a part, the method comprising:
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- arranging a component on a mandrel;
- fitting the mandrel into a mandrel recess of a moulding tool;
- arranging a panel with a first portion of the panel engaging a moulding surface of the moulding tool and a second portion of the panel engaging the component on the mandrel;
- bonding the first portion of the panel to the component by compressing them against the first mandrel; and
- moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool.
- The panel may be a variety of elements, depending on the application. In the preferred embodiments described below, the panel is either a wing skin or part of a capping layer which is wrapped around the moulding tool.
- A further aspect of the invention provides a method of manufacturing first and second parts, the method comprising:
-
- manufacturing the first part by:
- arranging a first component on a first mandrel;
- fitting the first mandrel into a mandrel recess of a moulding tool;
- arranging a first panel with a first portion of the panel engaging a moulding surface of the moulding tool and a second portion of the panel engaging the first component on the first mandrel;
- bonding the first portion of the panel to the first component by compressing them against the first mandrel; and
- moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool;
- removing the first mandrel from the mandrel recess; and
- manufacturing the second part by:
- arranging a second component on the second mandrel;
- fitting the second mandrel into the mandrel recess of the moulding tool;
- arranging a second panel with a first portion of the panel engaging the moulding surface of the moulding tool and a second portion of the panel engaging the second component on the second mandrel;
- bonding the first portion of the panel to the second component by compressing them against the second mandrel; and
- moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool.
- manufacturing the first part by:
- A further aspect of the invention provides a method of manufacturing a part, the method comprising:
-
- arranging a set of components on a moulding tool; and
- simultaneously compressing the set of components on the moulding tool against a panel so as to bond the components to the panel,
wherein the set of components includes a plurality of stringers, and one or more additional components.
- In one embodiment of the invention, the method further comprises:
-
- arranging a second set of components on the moulding tool; and
- compressing the second set of components on the moulding tool against a second panel so as to bond the second set of components to the second panel,
wherein the second set of components are compressed against the second panel at the same time that the first set of components are compressed against the first panel.
- For example in one of the embodiments described below the first set of components are stringers etc. associated with an upper surface of a wing-box, and the second set are stringers etc. associated with a lower surface of a wing-box.
- A further aspect of the invention provides a tool set comprising:
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- at least two inner mould line tools;
- at least two outer mould line tools; and
- one or more spacers, each adapted to be removably fitted between the inner mould line tools so as to maintain a desired spacing between the inner mould line tools.
- Such a tool set can be used in a method of manufacturing a part, the method comprising:
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- arranging a first set of components on an outer face of a first inner mould line tool;
- arranging a second set of components on an outer face of a second inner mould line tool;
- fitting one or more spacers between the inner mould line tools, with the spacer(s) engaging inner faces of the inner mould line tools so as to maintain a desired spacing between the inner mould line tools;
- forming a layer around the inner mould line tools;
- fitting outer mould line tools on opposite sides of the inner mould line tools;
- moulding the part by compressing the layer and the components between the inner and outer mould line tools;
- removing the spacer(s);
- disengaging the inner mould line tools from the part after the spacer(s) have been removed; and
- removing the inner mould line tools from the part.
- This method enables the inner mould line tools to be removed easily from the composite part after formation of the part. Typically the part is a tubular part such as a full wing-box.
- A further aspect of the invention provides a method of manufacturing a part, the method comprising:
-
- arranging a set of components on one or more inner mould line tools; forming a layer around the inner mould line tool(s);
- fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s);
- moulding the part by compressing the layer and the components between the inner and outer mould line tools; and
- removing the inner mould line tool(s) from the part.
- Typically the layer is formed by wrapping around the or each inner mould line tool. Typically the or each inner mould line tool is rotated as the layer is wrapped around the inner mould line tool(s), for instance by a filament winding machine.
- The various aspects of the invention may be used to form an aircraft part such as a full or half wing-box, or may be used in a variety of non-aircraft applications. The part is typically, although not exclusively, formed from a composite material.
- Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
-
FIG. 1 shows an Inner Mould Line (IML) tool for a half wing-box part; -
FIG. 2 a shows a first back-to-back mould tool; -
FIG. 2 b shows a second back-to-back mould tool; -
FIG. 3 shows the IML tool with the preforms and mandrels fitted; -
FIG. 4 shows a curing assembly for the half wing-box part; -
FIG. 5 shows an Inner Mould Line (IML) tool for a full wing-box part; -
FIG. 6 is a sectional view through a curing assembly for the full wing-box part; -
FIG. 7 shows the upper and lower Outer Mould Line (OML) used in the assembly ofFIG. 6 ; -
FIG. 8 is a side view of a Main Landing Gear (MLG) IML tool used in the assembly ofFIG. 6 ; -
FIG. 9 is a side view of a Pylon IML tool used in the assembly ofFIG. 6 ; -
FIG. 10 is a cross-sectional view showing one of the interfaces between the MLG IML tool and the wing-box IML tool in the assembly ofFIG. 6 ; -
FIGS. 11-18 show the production of a half wing-box part; and -
FIGS. 19-22 show the production of a full wing-box part. -
FIGS. 1 to 4 illustrate a process for manufacturing a half wing-box composite part. - An inner mould line (IML)
tool 1 shown inFIG. 1 comprises a contiguous piece of steel machined from a billet with an upper face defining an upper moulding surface. A pylon pad-uprecess 2 and a landing gear pad-uprecess 4 are machined in the leading and trailing edges of the upper moulding surface. Material is then removed from the upper moulding surface by machining to form a number of mandrel recesses. The mandrel recesses includespar channels 5 running spanwise along the leading and trailing edges of the tool, four stringer channels 6 running spanwise along the tool, and threerib foot channels 8 running chordwise across the tool. The stringer channels 6 andrib foot channels 8 each have a base and a pair of opposite side walls, whereas the spar channels, being formed at the edge of the upper moulding surface, have a base and only a single side wall. Mandrel locating holes are provided in the base of each mandrel recess. One ofsuch holes 9 is partially visible inFIG. 1 . The upper moulding surface is divided by the mandrel recesses into an array ofislands 3.Tool locating holes 7 are provided at the root end of thetool 1. - A flexible surface covering (such as a laminate of pre-cured plies) may be bonded or bolted to the upper moulding surface before the mandrel recesses have been formed. The flexible surface covering can then be machined to form a desired moulding profile, and punched through to form the tool and mandrel locating holes.
- A
stringer mould tool 10 is shown inFIG. 2 a. The tool comprises a pair ofmandrels mandrels mandrel 12. A row of stringer preforms 30, each formed from a pair of stringer halves, is shown inFIG. 3 . - The mandrels have location pins 13,14 which fit into the mandrel locator holes 9 in the base of the stringer recesses 6 to accurately locate the stringer mould tool. Although the male/female connection is provided in this case by male parts on the mandrels, and female holes in the mandrel recesses, in an alternative embodiment the male parts may be provided instead in the mandrel recesses.
- A trailing edge spar-
cap mandrel 34, shown inFIG. 3 , is used to mould a trailing edge spar-cap preform 33 in a similar manner to thestringers 30. That is, a charge (such as a prepreg) is placed on themandrel 34, and moulded the against two faces of the mandrel, for instance by vacuum forming. A leading edge spar-cap preform 31 is formed in a similar manner on a spar-cap mandrel 32. - Back-to-back rib foot tools (not shown), similar to the
stringer tool 10, are used to mould T-shaped rib foot preforms 36 shown inFIG. 3 . - An assembly line arrangement may be used to simultaneously manufacture the preforms, thus maximising the production rate.
- After the spar-cap, stringer and rib foot preforms have been formed, they are transported to the
IML tool 1 on their respective mandrels, and the mandrels are fitted into their respective channels in the tool as shown inFIG. 3 . The preforms may be cured or uncured prior to being fitted onto thetool 1. - Note that the two-sided channels (that is the stringer channels 6 and the rib foot channels 8) receive their respective mandrel as a push fit to accurately locate the mandrel.
-
FIG. 4 shows a curing assembly including theIML tool 1 and an outer mould line (OML)tool 40. TheOML tool 40 is located horizontally on a curing jig (not shown) using locating holes (not shown) in the tool. Askin 41 is laid onto theOML tool 40. Theskin 41 may be laid up by hand or using a tape laying machine, with prepreg or woven fabric. The IML tool 1 (with the preforms and mandrels in place as shown inFIG. 3 ) is inverted and placed on top of the skin to form the assembly shown inFIG. 4 . Dowel pins 42 extending from theOML tool 40 fit into the locating holes 7 (seeFIG. 1 ) in theIML tool 1 in order to accurately locate the IML and OML tools relative to each other. - The assembly of
FIG. 4 is then sealed and encapsulated between a pair of flexible diaphragms. A vacuum is applied between the diaphragms to compress the IML and OML tools together, and heat and pressure are applied in an autoclave to cure the components and bond them together. - During cure, the
skin 41 has a number of portions which engage with (and are compressed against) theislands 3 in theIML tool 1 and are thus moulded (on their inner face) to conform to the shape of theislands 3. Other portions of the skin engage with (and are compressed against) thestringers 30,rib feet 36, and sparcaps components - The resulting half-wing part is then removed from the mould tools, and manholes and any other critical areas are machined to provide a part ready for assembly. In the final assembly of the wing box, the
rib feet 36 are bolted to rib webs (not shown) and the spar-caps - The
IML tool 1 can be used as part of a modular tool set containing a number of different mandrels, each configured to fit into a mandrel recess and form a respective composite component. Thus for example thestringer mould tools 10 may be removed from the stringer mandrel channels 6 and substituted with alternative stringer mould tools which, whilst being shaped and sized to be received as a push fit into the channels 6, are configured to form a stringer of a different shape or size. Thus for example astringer mould tool 10′ shown inFIG. 2 b may be used to form an I-shapedstringer 30′ (instead of the T-shapedstringer 30 formed by the tool 10) in a subsequent co-curing/bonding process with a different skin. The same modular approach can be employed for the spar caps and rib feet. This enables thesame IML tool 1 to be used to form a number of different parts which each have a common general shape (as defined by theislands 3 which form the upper moulding surface) but have different components. This reduces the part count, thus minimising manufacturing costs. - The
IML tool 1 has stringer mandrel recesses 5, and additional mandrel recesses each configured to receive a mandrel for an additional component (in this case, spar caps and rib feet). This integrated tooling approach saves on manufacturing time since it enables the stringers, spar caps and rib feet to be simultaneously bonded to the skin. -
FIGS. 5 to 11 illustrate a process for manufacturing a full wing-box composite part. - An inner mould line (IML)
tool 50 shown inFIG. 5 comprises a contiguous piece of steel with an upper face defining an upper moulding surface, a lower face (opposite to the upper face) defining a lower moulding surface, and leading and trailing faces (adjacent to the upper and lower faces) defining leading and trailing moulding surfaces. A pylon pad-up recess 53 and a landing gear pad-up recess 52 are formed in the leading and trailing edges of the upper moulding surface. The moulding surfaces are then machined to form two pairs of upper andlower spar channels 55, upper andlower stringer channels 54 running spanwise along the tool, and upper and lowerrib foot channels 51 running chordwise across the tool. Only the upperrib foot channels 51 are shown inFIG. 5 , but similar rib channels are formed in the hidden lower moulding surface.Islands 58 are located between the channels. Rib post recesses 57 are formed in the leading and trailing moulding surfaces in line with therib foot channels 51. Only two rib post recesses 57 are shown inFIG. 5 , but a third rib post recess may be provided in line with therib foot channel 51 at the far end of the tool. Flats are formed in the lower moulding surface in the desired positions of manholes in the finished wing box. Only a single flat 56 at the root end of the IML tool is shown inFIG. 5 , but a number of such flats are positioned along the length of the hidden lower moulding surface. - A flexible surface covering (such as a laminate of pre-cured plies) may be wrapped around the tool 50 (and then bonded or bolted in place) before the mandrel recesses have been formed. The flexible surface covering can then be machined to form a desired moulding profile.
- Stringers, rib feet and spar caps are formed in a similar manner to the stringers, rib feet and spar caps shown in
FIG. 3 , and fitted in place in their respective recesses on theIML tool 50. Rib posts (not shown) are also moulded onto back-to-back tools similar to thetool stringer tool 10 shown inFIG. 3 , and the tools are fitted into the rib post recesses 57. - A set of four support struts 49 is shown in
FIG. 6 . A series of such sets of support struts 49 are mounted at intervals on ashaft 69 which runs along the centre line of thetool 50, with the ends of thestruts 49 engaging the inner corners of the tool. Theshaft 69 is rotated, and acapping layer 58 is wound onto theIML tool 50 by a filament winding machine as it rotates. Thecapping layer 58 comprises a series of capping plies. The fibres in most of the capping plies are likely to run at an angle of approximately 90° to the spanwise direction of the tool (that is, the axis of rotation of the tool). However, angles of up to 45° may be achieved by moving the spool of the filament winding machine at an angle to the shaft as the spool unwinds. -
FIG. 6 shows a curing assembly including theIML tool 50, an uppercover OML tool 53, a lowercover OML tool 54, a Main Landing Gear (MLG)IML tool 51, and aPylon IML tool 52. - The lower
cover OML tool 54 is located horizontally on a curing jig (not shown) with pins of the tooling jig passing through locating holes 56 (shown inFIG. 7 ) in thetool 54. Alower skin 57 is laid onto the lowercover OML tool 54. The IML tool 50 (with the preforms and mandrels in place as shown inFIG. 6 ) is placed on top of theskin 57 as shown inFIG. 6 , with the pins of the tooling jig passing through holes (not shown) in theIML tool 50 to accurately locate the IML and OML tools relative to each other. - The
MLG IML tool 51 andPylon IML tool 52 are then positioned in place as shown inFIG. 6 . - The
MLG IML tool 51 is shown in detail inFIG. 8 . Thetool 51 is symmetrical about its centre line, so only the upper half will be described in detail. The upper half comprises an upper caul plate with anupper face 60 which engages theupper skin 59 and aside face 64 which engages thecapping layer 58. The side face 64 extends into a flange with apilot hole 61. Apin 62 has anut 63 threaded onto its distal end (not shown). - The
nut 63 engages the nut carried by the lower caul plate, and one or both of the nuts can be rotated to adjust the spacing between the caul plates, thus ensuring accurate thickness for the upper andlower skins - An interface between the
MLG IML tool 51 and theIML tool 50 is shown inFIG. 10 . Thetool 51 may extend along the length of thetool 50, or may be located in line with the landing gear pad-up recess 52. Thetool 50 has apilot hole 65 aligned with thepilot hole 61 in thetool 51. Apilot hole 66 is punched through the capping layer 68 in line with the pilot holes 61,65. Abolt 80 is passed through the pilot holes 61,65,66 and held in place bynuts cylindrical collar 81 is fitted onto thebolt 80 and engages the opposed faces of thetools collar 81 is carefully controlled to accurately set the spacing between the tools, and thus the thickness of thecapping layer 58. - The
Pylon IML tool 52 is shown in detail inFIG. 9 . It has a similar construction to thetool 51 so will not be described in detail. Similar bolt interfaces are provided between thetool 52 and theIML tool 50. - The
tools - The upper
cover OML tool 53 is located horizontally on the curing jig using the pins on the curing jig passing through locatingholes 56 in thetool 53. Anupper skin 59 is laid onto the uppercover OML tool 53. Thetools skin 59, with the pins of the tooling jig passing through holes (not shown) in theIML tool 50 to accurately locate the IML and OML tools relative to each other. - The assembly of
FIG. 6 is then secured, sealed and bagged for curing in an autoclave. - The IML tool 50 (in common with the IML tool 1) can be used as part of a modular tool set containing a number of different mandrels, each configured to fit into a mandrel recess and form a respective composite component.
- The
IML tool 50 has stringer mandrel recesses, and additional mandrel recesses each configured to receive a mandrel for an additional component (in this case, spar caps, rib posts and rib feet). This integrated tooling approach saves on manufacturing time since it enables the stringers, spar caps, rib posts and rib feet to be simultaneously bonded. Also, the full wing-box IML tool enables the upper and lower skins to be bonded to their respective components at the same time, reducing assembly time and cost compared with the half wing-box version. Also, there is no additional assembly step required to bolt the spar caps to a spar web—the spar web being provided by thecapping layer 58. - However the half-wing box version, producing a smaller part, enables non-destructive testing to be performed more easily on the part.
- The OML tools are then removed, and the IML tools removed from the larger root end of the full wing-box part. Manholes and any other critical areas are then machined to provide a part ready for assembly. During assembly, rib webs are passed through the root end of the wing-box and bolted to the rib posts and rib feet. Some additional bolting of the spar caps to the
skins -
FIGS. 11-16 illustrate an alternative process for manufacturing a half wing-box composite part. The process is similar to the process shown inFIGS. 1-4 , and only the differences will be described in detail. AnIML tool 100 shown inFIG. 13 is formed from abillet 101 shown inFIG. 11 which is first machined to form the inner mould line surface, spar channels and pad-up recesses as shown inFIG. 12 , and then machined to form the stringer and rib foot recesses as shown inFIG. 13 . Thetool 100 receives the same mandrels as thetool 1, and these are shown individually inFIG. 13 prior to insertion into their respective mandrel recesses.FIG. 14 shows the mandrels and preforms in place, andFIG. 15 shows acapping layer 102 which is then draped onto the tool. -
Caul plates FIG. 16 . As shown inFIG. 17 , askin 105 is laid onto anOML tool 106. Thetool 100 is placed onto theskin 105 as shown inFIG. 18 , and dowel pins extending from aplate 111 are inserted into holes in the OML tool and caul plates to accurately position the parts. Four of the dowel pins 107-110 are shown inFIG. 18 , the other dowel pins being hidden. The assembly ofFIG. 18 is then bagged, and cured in an autoclave. -
FIGS. 19-22 illustrate an alternative process for manufacturing a full wing-box composite part. A pair ofIML tools IML tool 100 are fitted with preforms as shown inFIG. 21 . Fourintercostal spacer plates 122, shown inFIG. 19 , are removably fitted between theIML tools capping layer 123 is then wound onto the assembly as shown inFIG. 21 . In contrast with the assembly ofFIG. 6 in which the assembly is rotated on a shaft which runs along the centre line of the tool, the assembly ofFIG. 21 can be rotated by thespacer plates 122. - After the
capping layer 123 has been formed,caul plates FIG. 20 are fitted as shown inFIG. 22 . Upper andlower OML tools 126,127 (both carrying skins, not labelled) are then fitted as shown inFIG. 22 . The assembly ofFIG. 22 is then bagged, and cured in an autoclave. - After curing, the
OML tools caul plates intercostal spacer plates 122 can then be removed from the root and tip end of the wing box, or from the leading and trailing edges. This then enables theIML tools upper tool 121 down, and moving thelower tool 120 up) and removed from the root end or the tip end. - Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.
Claims (21)
1-31. (canceled)
32. A method of manufacturing a part, the method comprising:
forming a component on a mandrel;
fitting the mandrel into a mandrel recess of a moulding tool;
arranging a panel with a first portion of the panel engaging a moulding surface of the moulding tool and a second portion of the panel engaging the component on the mandrel;
bonding the first portion of the panel to the component by compressing them against the mandrel; and
moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool.
33. A method of manufacturing first and second parts, the method comprising:
manufacturing the first part by the method of claim 32 , wherein the component is a first component, the mandrel is a first mandrel, and the panel is a first panel;
removing the first mandrel from the mandrel recess; and
manufacturing the second part by repeating the method of claim 1, wherein the component is a second component, the mandrel is a second mandrel, and the panel is a second panel.
34. A moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, wherein the mandrel recess has a mandrel locator configured to engage with a mandrel so as to locate the mandrel at a desired position in the mandrel recess.
35. The tool of claim 34 wherein the mandrel locator is configured to engage with the mandrel by means of a male/female connection.
36. The tool of claim 35 wherein the mandrel locator comprises a hole in the mandrel recess.
37. The tool of claim 34 comprising a plurality of mandrel recesses formed in the moulding surface.
38. The tool of claim 37 wherein the mandrel recesses are formed in a contiguous piece of material.
39. The tool of claim 37 comprising:
two or more stringer mandrel recesses in the moulding surface, each configured to receive a respective stringer mandrel; and
one or more additional mandrel recesses in the moulding surface, each configured to receive a mandrel for an additional component.
40. A method of manufacturing the moulding tool of claim 34 , the method comprising forming each mandrel recess by removing material from the moulding tool.
41. A tool set comprising:
a moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, and
a mandrel configured to fit into the mandrel recess and form a component.
42. A tool set comprising:
the moulding tool of claim 37 ;
two or more stringer mandrels each configured to fit into a respective one of the stringer mandrel recesses and form a respective stringer; and
one or more additional mandrels each configured to fit into a respective one of the additional mandrel recesses and form a respective additional component.
43. A method of manufacturing a part, the method comprising:
arranging a set of components on a moulding tool; and
simultaneously compressing the set of components on the moulding tool against a panel so as to bond the components to the panel,
wherein the set of components includes a plurality of stringers, and one or more additional components.
44. The method of claim 43 further comprising:
arranging a second set of components on the moulding tool; and
compressing the second set of components on the moulding tool against a second panel so as to bond the second set of components to the second panel,
wherein the second set of components are compressed against the second panel at the same time that the first set of components are compressed against the first panel.
45. A tool set comprising:
at least two inner mould line tools;
at least two outer mould line tools; and
one or more spacers, each adapted to be removably fitted between the inner mould line tools so as to maintain a desired spacing between the inner mould line tools.
46. A method of manufacturing a part, the method comprising:
arranging a first set of components on an outer face of a first inner mould line tool;
arranging a second set of components on an outer face of a second inner mould line tool;
fitting one or more spacers between the inner mould line tools, with the spacer(s) engaging inner faces of the inner mould line tools so as to maintain a desired spacing between the inner mould line tools;
forming a layer around the inner mould line tools;
fitting outer mould line tools on opposite sides of the inner mould line tools;
moulding the part by compressing the layer and the components between the inner and outer mould line tools;
removing the spacer(s);
disengaging the inner mould line tools from the part after the spacer(s) have been removed; and
removing the inner mould line tools from the part.
47. A method of manufacturing a part, the method comprising:
arranging a set of components on one or more inner mould line tools;
forming a layer around the inner mould line tool(s);
fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s);
moulding the part by compressing the layer and the components between the inner and outer mould line tools; and
removing the inner mould line tool(s) from the part.
48. The method of claim 46 wherein the layer is formed by wrapping around the or each inner mould line tool.
49. The method of claim 48 wherein the or each inner mould line tool is rotated as the layer is wrapped around the inner mould line tool(s).
50. The method of claim 47 wherein the layer is formed by wrapping around the or each inner mould line tool.
51. A tool set comprising:
the moulding tool of claim 34 ; and
a mandrel configured to fit into the mandrel recess and form a component.
Applications Claiming Priority (3)
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PCT/GB2007/002819 WO2008020158A2 (en) | 2006-08-14 | 2007-07-25 | Moulding tool and method of manufacturing a part bonding for example spars on a skin |
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PCT/GB2007/002819 A-371-Of-International WO2008020158A2 (en) | 2006-08-14 | 2007-07-25 | Moulding tool and method of manufacturing a part bonding for example spars on a skin |
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Also Published As
Publication number | Publication date |
---|---|
JP5301440B2 (en) | 2013-09-25 |
EP2815862B1 (en) | 2017-10-04 |
JP5770786B2 (en) | 2015-08-26 |
EP2815862A1 (en) | 2014-12-24 |
US9481115B2 (en) | 2016-11-01 |
CA2660964C (en) | 2015-12-01 |
BRPI0716613A2 (en) | 2013-10-08 |
CN101500773B (en) | 2014-03-05 |
US20130240130A1 (en) | 2013-09-19 |
JP2013230687A (en) | 2013-11-14 |
RU2009107009A (en) | 2010-09-27 |
CA2660964A1 (en) | 2008-02-21 |
EP2051838A2 (en) | 2009-04-29 |
CN101500773A (en) | 2009-08-05 |
GB0616121D0 (en) | 2006-09-20 |
WO2008020158A2 (en) | 2008-02-21 |
RU2457111C2 (en) | 2012-07-27 |
WO2008020158A3 (en) | 2008-05-08 |
JP2010500199A (en) | 2010-01-07 |
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