Cutting wire for removal of expanded material after curing of a composite part
AssigneeThe Boeing Company
InventorsGary E. Georgeson, Xiaoxi Wang, Jonathan Santiago
Life of this patent
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Abstract
Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.
Claims20
A method of fabricating a composite part, the method comprising:
- placing one or more composite layers on a molding tool to form a layup, wherein at least a portion of the layup is within a constrained space;
- activating a foamable material to expand into an expanded material within the constrained space;
- curing the layup while the expanded material presses the layup against the molding tool to form the composite part;
- boring a hole through the expanded material after curing;
- threading a cutting wire through the hole in the expanded material;
- controlling a manipulator comprising a robotic arm, with a controller, to perform automated tasks of:
- grasping opposing ends of the cutting wire with end effectors that make an electrical coupling with the cutting wire;
- heating the cutting wire with current applied through the cutting wire via the electrical coupling;
- and
- moving the cutting wire within the constrained space to cut the expanded material into pieces;
- and
- removing the pieces from the constrained space.
A method of fabricating a composite part, the method comprising:
- placing composite layers on a molding tool to form a layup, wherein at least a portion of the layup is within a constrained space created by a shape of the molding tool;
- heating the molding tool and the layup in a curing device, wherein the heating activates a foamable material to expand within the constrained space into an expanded material that presses the layup against the forming surfaces of the molding tool, and cures the layup to form the composite part;
- boring a hole through the expanded material after curing;
- threading a cutting wire through the hole in the expanded material;
- controlling a manipulator comprising a robotic arm, with a controller, to perform automated tasks of:
- grasping opposing ends of the cutting wire with end effectors that make an electrical coupling with the cutting wire;
- heating the cutting wire with current applied through the cutting wire via the electrical coupling;
- and
- moving the cutting wire while heated within the constrained space to cut the expanded material into pieces;
- and
- removing the pieces from the constrained space.
A composite fabrication system, comprising:
- a molding tool that includes a forming surface upon which one or more composite layers are placed to form a layup, wherein at least a portion of the forming surface is disposed within a constrained space;
- a foamable material activated to expand into an expanded material within the constrained space;
- a curing device configured to cure the layup while the expanded material presses the layup against the molding tool to form a composite part;
- and
- a removal tool configured to bore a hole through the expanded material after curing, and comprising a cutting wire threaded through the hole in the expanded material, and a manipulator comprising a robotic arm and controlled with a controller to perform automated tasks of:
- grasping opposing ends of the cutting wire with end effectors that make an electrical coupling with the cutting wire;
- heating the cutting wire with current applied through the cutting wire via the electrical coupling, and
- moving the cutting wire within the constrained space to cut the expanded material into pieces;
- the removal tool is configured to remove the pieces from the constrained space.
Dependencies are inferred from the claim text.