U.S. patent application number 12/310138 was filed with the patent office on 2010-01-07 for moulding tool and method of manufacturing a part.
Invention is credited to Marc Edwin Funnell.
Application Number | 20100000667 12/310138 |
Document ID | / |
Family ID | 37056315 |
Filed Date | 2010-01-07 |
United States Patent
Application |
20100000667 |
Kind Code |
A1 |
Funnell; Marc Edwin |
January 7, 2010 |
MOULDING TOOL AND METHOD OF MANUFACTURING A PART
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.
Inventors: |
Funnell; Marc Edwin;
(Bristol, GB) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
901 NORTH GLEBE ROAD, 11TH FLOOR
ARLINGTON
VA
22203
US
|
Family ID: |
37056315 |
Appl. No.: |
12/310138 |
Filed: |
July 25, 2007 |
PCT Filed: |
July 25, 2007 |
PCT NO: |
PCT/GB2007/002819 |
371 Date: |
February 12, 2009 |
Current U.S.
Class: |
156/189 ;
264/241; 425/394 |
Current CPC
Class: |
B29C 33/48 20130101;
B64C 3/182 20130101; B64C 3/187 20130101; B29D 99/0014 20130101;
B64C 3/24 20130101; B29C 70/446 20130101; B29C 33/485 20130101;
B29C 70/342 20130101; B29K 2105/0809 20130101; B29D 99/0028
20130101; B29C 43/021 20130101; B29C 70/32 20130101; B29C 33/306
20130101; B29L 2031/3085 20130101; Y02T 50/43 20130101; Y02T 50/40
20130101; B29K 2105/0872 20130101; B29C 70/44 20130101 |
Class at
Publication: |
156/189 ;
264/241; 425/394 |
International
Class: |
B29C 53/60 20060101
B29C053/60; B28B 7/28 20060101 B28B007/28; B28B 21/22 20060101
B28B021/22 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 14, 2006 |
GB |
0616121.0 |
Claims
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.
Description
FIELD OF THE INVENTION
[0001] 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.
BACKGROUND OF THE INVENTION
[0002] 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.
SUMMARY OF THE INVENTION
[0003] 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.
[0004] Providing a mandrel recess in the moulding surface enables a
mandrel to be fitted easily and accurately relative to the moulding
surface.
[0005] Typically the mandrel locator is configured to engage with
the mandrel by means of a male/female connection (such as a hole or
pin).
[0006] 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.
[0007] 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.
[0008] Typically each recess has been formed by removing material
from the moulding tool--for instance by machining from a
billet.
[0009] A further aspect of the invention provides a tool set
comprising: [0010] a moulding tool according to the first aspect of
the invention; [0011] a first mandrel configured to fit into the
mandrel recess and form a first component; and [0012] 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.
[0013] 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.
[0014] A further aspect of the invention provides a tool set
comprising: [0015] a moulding tool according to the first aspect of
the invention; [0016] two or more stringer mandrels each configured
to fit into a respective one of the stringer mandrel recesses and
form a respective stringer; and [0017] one or more additional
mandrels each configured to fit into a respective one of the
additional mandrel recesses and form a respective additional
component.
[0018] Thus the moulding tool can accommodate mandrels for
stringers and also for additional components such as rib feet,
spars and/or rib posts.
[0019] A further aspect of the invention provides a method of
manufacturing a part, the method comprising: [0020] arranging a
component on a mandrel; [0021] fitting the mandrel into a mandrel
recess of a moulding tool; [0022] 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; [0023] bonding the first portion of the panel to the
component by compressing them against the first mandrel; and [0024]
moulding the second portion of the panel by compressing it against
the moulding surface of the moulding tool.
[0025] 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.
[0026] A further aspect of the invention provides a method of
manufacturing first and second parts, the method comprising: [0027]
manufacturing the first part by: [0028] arranging a first component
on a first mandrel; [0029] fitting the first mandrel into a mandrel
recess of a moulding tool; [0030] 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; [0031] bonding the first portion of
the panel to the first component by compressing them against the
first mandrel; and [0032] moulding the second portion of the panel
by compressing it against the moulding surface of the moulding
tool; [0033] removing the first mandrel from the mandrel recess;
and [0034] manufacturing the second part by: [0035] arranging a
second component on the second mandrel; [0036] fitting the second
mandrel into the mandrel recess of the moulding tool; [0037]
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;
[0038] bonding the first portion of the panel to the second
component by compressing them against the second mandrel; and
[0039] moulding the second portion of the panel by compressing it
against the moulding surface of the moulding tool.
[0040] A further aspect of the invention provides a method of
manufacturing a part, the method comprising: [0041] arranging a set
of components on a moulding tool; and [0042] 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.
[0043] In one embodiment of the invention, the method further
comprises: [0044] arranging a second set of components on the
moulding tool; and [0045] 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.
[0046] 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.
[0047] A further aspect of the invention provides a tool set
comprising: [0048] at least two inner mould line tools; [0049] at
least two outer mould line tools; and [0050] 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.
[0051] Such a tool set can be used in a method of manufacturing a
part, the method comprising: [0052] arranging a first set of
components on an outer face of a first inner mould line tool;
[0053] arranging a second set of components on an outer face of a
second inner mould line tool; [0054] 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; [0055] forming
a layer around the inner mould line tools; [0056] fitting outer
mould line tools on opposite sides of the inner mould line tools;
[0057] moulding the part by compressing the layer and the
components between the inner and outer mould line tools; [0058]
removing the spacer(s); [0059] disengaging the inner mould line
tools from the part after the spacer(s) have been removed; and
[0060] removing the inner mould line tools from the part.
[0061] 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.
[0062] A further aspect of the invention provides a method of
manufacturing a part, the method comprising: [0063] arranging a set
of components on one or more inner mould line tools; forming a
layer around the inner mould line tool(s); [0064] fitting a pair of
outer mould line tools on opposite sides of the inner mould line
tool(s); [0065] moulding the part by compressing the layer and the
components between the inner and outer mould line tools; and [0066]
removing the inner mould line tool(s) from the part.
[0067] 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.
[0068] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0069] Embodiments of the invention will now be described with
reference to the accompanying drawings, in which:
[0070] FIG. 1 shows an Inner Mould Line (IML) tool for a half
wing-box part;
[0071] FIG. 2a shows a first back-to-back mould tool;
[0072] FIG. 2b shows a second back-to-back mould tool;
[0073] FIG. 3 shows the IML tool with the preforms and mandrels
fitted;
[0074] FIG. 4 shows a curing assembly for the half wing-box
part;
[0075] FIG. 5 shows an Inner Mould Line (IML) tool for a full
wing-box part;
[0076] FIG. 6 is a sectional view through a curing assembly for the
full wing-box part;
[0077] FIG. 7 shows the upper and lower Outer Mould Line (OML) used
in the assembly of FIG. 6;
[0078] FIG. 8 is a side view of a Main Landing Gear (MLG) IML tool
used in the assembly of FIG. 6;
[0079] FIG. 9 is a side view of a Pylon IML tool used in the
assembly of FIG. 6;
[0080] 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 of FIG. 6;
[0081] FIGS. 11-18 show the production of a half wing-box part;
and
[0082] FIGS. 19-22 show the production of a full wing-box part.
DETAILED DESCRIPTION OF EMBODIMENT(S)
[0083] FIGS. 1 to 4 illustrate a process for manufacturing a half
wing-box composite part.
[0084] An inner mould line (IML) tool 1 shown in FIG. 1 comprises a
contiguous piece of steel machined from a billet with an upper face
defining an upper moulding surface. A pylon pad-up recess 2 and a
landing gear pad-up recess 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 include spar
channels 5 running spanwise along the leading and trailing edges of
the tool, four stringer channels 6 running spanwise along the tool,
and three rib foot channels 8 running chordwise across the tool.
The stringer channels 6 and rib 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 of such holes 9 is partially
visible in FIG. 1. The upper moulding surface is divided by the
mandrel recesses into an array of islands 3. Tool locating holes 7
are provided at the root end of the tool 1.
[0085] 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.
[0086] A stringer mould tool 10 is shown in FIG. 2a. The tool
comprises a pair of mandrels 11,12 arranged back-to-back. The
mandrels 11,12 are similar in form and so only mandrel 11 will be
described in detail. A stringer half is formed on the mandrel by
laying a laminate charge (such as a prepreg) on the mandrel, and
moulding the charge against two faces 15,16 of the mandrel. This
may be achieved by a variety of manufacturing techniques. For
example a flexible diaphragm may be laid over the charge, and one
side of the diaphragm evacuated to mould the charge using
hydrostatic pressure (in combination with heat). This results in an
L-shaped stringer half, which is laid back to back with another
stringer half formed over mandrel 12. A row of stringer preforms
30, each formed from a pair of stringer halves, is shown in FIG.
3.
[0087] 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.
[0088] A trailing edge spar-cap mandrel 34, shown in FIG. 3, is
used to mould a trailing edge spar-cap preform 33 in a similar
manner to the stringers 30. That is, a charge (such as a prepreg)
is placed on the mandrel 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.
[0089] 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 in FIG. 3.
[0090] An assembly line arrangement may be used to simultaneously
manufacture the preforms, thus maximising the production rate.
[0091] 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 in FIG. 3. The preforms may be cured
or uncured prior to being fitted onto the tool 1.
[0092] 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.
[0093] FIG. 4 shows a curing assembly including the IML tool 1 and
an outer mould line (OML) tool 40. The OML tool 40 is located
horizontally on a curing jig (not shown) using locating holes (not
shown) in the tool. A skin 41 is laid onto the OML tool 40. The
skin 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 in FIG. 3) is inverted and placed on top
of the skin to form the assembly shown in FIG. 4. Dowel pins 42
extending from the OML tool 40 fit into the locating holes 7 (see
FIG. 1) in the IML tool 1 in order to accurately locate the IML and
OML tools relative to each other.
[0094] 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.
[0095] During cure, the skin 41 has a number of portions which
engage with (and are compressed against) the islands 3 in the IML
tool 1 and are thus moulded (on their inner face) to conform to the
shape of the islands 3. Other portions of the skin engage with (and
are compressed against) the stringers 30, rib feet 36, and spar
caps 31,33 so as to bond them together. The components 30,36,31,33
are compressed and moulded on their other side by their respective
mandrels.
[0096] 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 31,33 are bolted to spar webs (not shown). The rib
webs and spar webs are bolted in turn to another similar half-wing
part (also not shown). Some additional bolting of the spar caps may
be required in areas of high shear.
[0097] 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 the stringer 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 a
stringer mould tool 10' shown in FIG. 2b may be used to form an
I-shaped stringer 30' (instead of the T-shaped stringer 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 the same IML tool 1 to be used
to form a number of different parts which each have a common
general shape (as defined by the islands 3 which form the upper
moulding surface) but have different components. This reduces the
part count, thus minimising manufacturing costs.
[0098] 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.
[0099] FIGS. 5 to 11 illustrate a process for manufacturing a full
wing-box composite part.
[0100] An inner mould line (IML) tool 50 shown in FIG. 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 and lower spar channels 55,
upper and lower stringer channels 54 running spanwise along the
tool, and upper and lower rib foot channels 51 running chordwise
across the tool. Only the upper rib foot channels 51 are shown in
FIG. 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 the rib foot channels 51. Only two rib post
recesses 57 are shown in FIG. 5, but a third rib post recess may be
provided in line with the rib 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 in FIG. 5, but a number
of such flats are positioned along the length of the hidden lower
moulding surface.
[0101] 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.
[0102] 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 the IML tool
50. Rib posts (not shown) are also moulded onto back-to-back tools
similar to the tool stringer tool 10 shown in FIG. 3, and the tools
are fitted into the rib post recesses 57.
[0103] 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 a
shaft 69 which runs along the centre line of the tool 50, with the
ends of the struts 49 engaging the inner corners of the tool. The
shaft 69 is rotated, and a capping layer 58 is wound onto the IML
tool 50 by a filament winding machine as it rotates. The capping
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.degree. to the spanwise direction of the tool (that is, the axis
of rotation of the tool). However, angles of up to 45.degree. may
be achieved by moving the spool of the filament winding machine at
an angle to the shaft as the spool unwinds.
[0104] FIG. 6 shows a curing assembly including the IML tool 50, an
upper cover OML tool 53, a lower cover OML tool 54, a Main Landing
Gear (MLG) IML tool 51, and a Pylon IML tool 52.
[0105] 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 in FIG. 7) in the tool 54. A lower skin 57
is laid onto the lower cover OML tool 54. The IML tool 50 (with the
preforms and mandrels in place as shown in FIG. 6) is placed on top
of the skin 57 as shown in FIG. 6, with the pins of the tooling jig
passing through holes (not shown) in the IML tool 50 to accurately
locate the IML and OML tools relative to each other.
[0106] The MLG IML tool 51 and Pylon IML tool 52 are then
positioned in place as shown in FIG. 6.
[0107] The MLG IML tool 51 is shown in detail in FIG. 8. The tool
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 an upper face 60 which engages the upper skin 59 and a
side face 64 which engages the capping layer 58. The side face 64
extends into a flange with a pilot hole 61. A pin 62 has a nut 63
threaded onto its distal end (not shown).
[0108] 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 and lower skins 57,59.
[0109] An interface between the MLG IML tool 51 and the IML tool 50
is shown in FIG. 10. The tool 51 may extend along the length of the
tool 50, or may be located in line with the landing gear pad-up
recess 52. The tool 50 has a pilot hole 65 aligned with the pilot
hole 61 in the tool 51. A pilot hole 66 is punched through the
capping layer 68 in line with the pilot holes 61,65. A bolt 80 is
passed through the pilot holes 61,65,66 and held in place by nuts
82, 83. A cylindrical collar 81 is fitted onto the bolt 80 and
engages the opposed faces of the tools 50,51. The length of the
collar 81 is carefully controlled to accurately set the spacing
between the tools, and thus the thickness of the capping layer
58.
[0110] The Pylon IML tool 52 is shown in detail in FIG. 9. It has a
similar construction to the tool 51 so will not be described in
detail. Similar bolt interfaces are provided between the tool 52
and the IML tool 50.
[0111] The tools 50,51,52 are then secured, removed from the jig,
and rotated by 180.degree..
[0112] The upper cover OML tool 53 is located horizontally on the
curing jig using the pins on the curing jig passing through
locating holes 56 in the tool 53. An upper skin 59 is laid onto the
upper cover OML tool 53. The tools 50,51,52 are then placed on top
of the skin 59, with the pins of the tooling jig passing through
holes (not shown) in the IML tool 50 to accurately locate the IML
and OML tools relative to each other.
[0113] The assembly of FIG. 6 is then secured, sealed and bagged
for curing in an autoclave.
[0114] 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.
[0115] 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 the capping layer 58.
[0116] However the half-wing box version, producing a smaller part,
enables non-destructive testing to be performed more easily on the
part.
[0117] 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 57,59 may be
required in areas of high shear.
[0118] FIGS. 11-16 illustrate an alternative process for
manufacturing a half wing-box composite part. The process is
similar to the process shown in FIGS. 1-4, and only the differences
will be described in detail. An IML tool 100 shown in FIG. 13 is
formed from a billet 101 shown in FIG. 11 which is first machined
to form the inner mould line surface, spar channels and pad-up
recesses as shown in FIG. 12, and then machined to form the
stringer and rib foot recesses as shown in FIG. 13. The tool 100
receives the same mandrels as the tool 1, and these are shown
individually in FIG. 13 prior to insertion into their respective
mandrel recesses. FIG. 14 shows the mandrels and preforms in place,
and FIG. 15 shows a capping layer 102 which is then draped onto the
tool.
[0119] Caul plates 103,104 are then fitted to the leading and
trailing edges as shown in FIG. 16. As shown in FIG. 17, a skin 105
is laid onto an OML tool 106. The tool 100 is placed onto the skin
105 as shown in FIG. 18, and dowel pins extending from a plate 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 in FIG. 18, the other dowel pins being hidden. The assembly
of FIG. 18 is then bagged, and cured in an autoclave.
[0120] FIGS. 19-22 illustrate an alternative process for
manufacturing a full wing-box composite part. A pair of IML tools
120,121 similar to the IML tool 100 are fitted with preforms as
shown in FIG. 21. Four intercostal spacer plates 122, shown in FIG.
19, are removably fitted between the IML tools 121,120. The upper
and lower faces of the spacer plates engage the inner faces of the
inner mould line tools so as to maintain a desired spacing between
them. A capping layer 123 is then wound onto the assembly as shown
in FIG. 21. In contrast with the assembly of FIG. 6 in which the
assembly is rotated on a shaft which runs along the centre line of
the tool, the assembly of FIG. 21 can be rotated by the spacer
plates 122.
[0121] After the capping layer 123 has been formed, caul plates
124,125 shown in FIG. 20 are fitted as shown in FIG. 22. Upper and
lower OML tools 126,127 (both carrying skins, not labelled) are
then fitted as shown in FIG. 22. The assembly of FIG. 22 is then
bagged, and cured in an autoclave.
[0122] After curing, the OML tools 126,127 and caul plates 124,125
are removed. The four 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 the IML tools 120,121
to be disengaged from the cured wing box (by moving the upper tool
121 down, and moving the lower tool 120 up) and removed from the
root end or the tip end.
[0123] 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.
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