Net shape forming of composite stringers containing out-of-plane features
AssigneeThe Boeing Company
InventorsSteven Joseph Plummer, Kurtis Shuldberg Willden, Andrew Elmer Modin, Raviendra S. Suriyaarachchi, Megan E. Bliss
Life of this patent
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Abstract
A tool is configured to form a composite charge into a stringer having a net shape with at least one out-of-place feature. The out-of-plane feature is formed by a shim removably attached to the tool. A family of the shims may be used to form a range of out-of-plane features having varying characteristics.
Claims20
Apparatus for making a composite stringer having at least one out-of-plane feature, comprising:
- a die including a die cavity;
- a tool configured to form a composite charge into the die cavity;
- a shim attached to the tool and configured to form an out-of-plane feature in the composite stringer in the form of a joggle along a length of the composite stringer as the tool forms the composite charge into the die cavity, wherein the shim has a cross-sectional profile that matches a cross-sectional shape of the tool and wherein the cross-sectional profile of the shim matches a cross-sectional shape of the out-of-plane feature;
- and
- wherein the shim includes:
- a cap, sides, and flanges which form the cross-sectional profile of the shim;
- a set of first openings therein that extend completely across the cap and the sides allowing the shim to flex;
- and
- a set of second openings therein that extend fully across the cap but only partially through the sides into which the composite charge may strain as the composite charge is formed by the tool.
Apparatus for making a composite stringer, comprising:
- a punch;
- a die into which a composite charge may be formed by the punch;
- a family of shims respectively configured to form differing features in the composite charge along a length of the composite charge, wherein each shim of the family of shims has a cross-sectional profile that matches a cross-sectional shape of the punch and wherein the cross-sectional profile of each shim matches a cross-sectional shape of a respective feature of the differing features;
- each shim of the family of shims being configured to be releasably attached to the punch;
- and
- wherein at least one shim of the family of shims includes:
- a cap, sides, and flanges which form the cross-sectional profile of the shim;
- a set of first openings therein that extend completely across the cap and the sides allowing the shim to flex;
- and
- a set of second openings therein that extend fully across the cap but only partially through the sides.
A method of making a composite stringer having an out-of-plane feature to net shape, comprising:
- forming a die cavity in a die;
- installing a shim on a tool, the shim configured to form an out-of-plane feature along a length of a composite stringer, wherein the shim includes a cap, sides, and flanges which form a cross-sectional profile of the shim;
- forming a composite charge into the die cavity and forming the composite stringer using the tool, including using the shim to form the out-of-plane feature in the composite charge as the composite charge is formed by the tool, wherein the cross-sectional profile of the shim matches a cross-sectional shape of the tool and wherein the cross-sectional profile of the shim matches a cross-sectional shape of the out-of-plane feature;
- and
- forming a plurality of first openings in the shim that extend completely across the cap and the sides and forming a plurality of second openings in the shim that extend fully across the cap but only partially through the sides.
Dependencies are inferred from the claim text.