Apparatus and method to enable in-plane bending of high contour composite structures in post-forming operations

A forming apparatus for forming a high contour composite structure, the forming apparatus comprising:

• an upper die assembly comprising a plurality of compressor module assemblies comprising compressor modules movably coupled to upper actuator assemblies, and coupled to a pair of lateral pressure plates, with a punch disposed between the pair of lateral pressure plates;
• a lower die assembly comprising a lower pallet coupled to lower actuator assemblies, and having a presser apparatus disposed between pairs of die portions spaced apart to define a lower die cavity, the die portions being slidably displaceable with respect to each other, and the lower die assembly being separate from the upper die assembly, between which a composite charge having ply discontinuity features formed through one or more portions is formed;
• a plurality of load cells coupled to, and aligned between, the upper actuator assemblies and the compressor modules of the upper die assembly, to monitor pressure applied to the composite charge by the upper actuator assemblies;
• and
• a control system having a controller to operably control the upper actuator assemblies and the lower actuator assemblies,
• wherein the upper die assembly, the lower die assembly, or a combination of the upper die assembly and the lower die assembly, is segmented into separate and independently movable segments having gaps formed between the separate and independently movable segments, and the separate and independently movable segments are controlled, with the controller, to vary pressure and a through thickness compaction to the one or more portions of the composite charge, along a length of the composite charge, during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure, formed by the composite charge, in one or more post-forming operations.

A method to enable in-plane bending of a high contour composite structure in one or more post-forming operations, the method comprising the steps of:

• providing a forming apparatus comprising:
• an upper die and a lower die between which a composite charge is formed, the upper die having upper die portions that are slidably displaceable, via first actuators, and the lower die having pairs of die blocks spaced apart to define a die cavity, and slidably displaceable, via second actuators;
• a plurality of load cells coupled to the first actuators, to monitor pressure applied to the composite charge by the first actuators and the second actuators;
• a control system having a controller to operably control the first actuators and the second actuators;
• and
• an overlay tool assembly coupled to the upper die, the overlay tool assembly having scalloped sections positioned between pairs of the plurality of load cells along a length of the upper die, and positioned against one or more portions of the composite charge during a forming process;
• positioning the composite charge between the upper die and the lower die, the composite charge having ply discontinuity features formed through a thickness of one or more portions of the composite charge;
• aligning the ply discontinuity features between the pairs of the plurality of load cells;
• positioning the scalloped sections of the overlay tool assembly against the one or more portions of the composite charge, and aligning the scalloped sections with the ply discontinuity features;
• forming the composite charge with the forming apparatus and a forming process;
• using the overlay tool assembly to deny pressure and a through thickness compaction to the one or more portions of the composite charge during the forming process, to allow one or more plies in the one or more portions to move after the forming process;
• and
• obtaining the high contour composite structure, formed by the composite charge, enabled for the in-plane bending in the one or more post-forming operations.

A method to enable in-plane bending of a high contour composite structure in one or more post-forming operations, the method comprising the steps of:

• providing a forming apparatus comprising:
• an upper die assembly comprising a plurality of compressor module assemblies comprising compressor modules movably coupled to upper actuator assemblies, and coupled to a pair of lateral pressure plates, with a punch disposed between the pair of lateral pressure plates;
• a lower die assembly comprising a lower pallet coupled to lower actuator assemblies, and having a presser apparatus disposed between pairs of die portions spaced apart to define a lower die cavity, the die portions being slidably displaceable with respect to each other, and the lower die assembly being separate from the upper die assembly, between which a composite charge having ply discontinuity features formed through one or more portions is formed;
• a plurality of load cells coupled to, and aligned between, the upper actuator assemblies and the compressor modules of the upper die assembly, to monitor pressure applied to the composite charge by the upper actuator assemblies;
• and
• a control system having a controller to operably control the upper actuator assemblies and the lower actuator assemblies,
• wherein one of the upper die assembly, the lower die assembly, or a combination of the upper die assembly and the lower die assembly, is segmented into separate and independently movable segments having gaps formed between the separate and independently movable segments;
• positioning the composite charge between the upper die assembly and the lower die assembly;
• forming the composite charge with the forming apparatus and a forming process;
• using the controller to independently control the separate and independently movable segments, to vary pressure and a through thickness compaction to the one or more portions of the composite charge, along a length of the composite charge, during the forming process, to allow one or more plies in the one or more portions to move after the forming process;
• and
• obtaining the high contour composite structure, formed by the composite charge, enabled for the in-plane bending in the one or more post-forming operations.