Mandrel for forming a component

A forming station comprising:

• At least one mandrel mandrel having a longitudinal axis and defining a cavity profile, the mandrel comprising:
• a support structure;
• a plurality of main sectors carried by the support structure and each having a main forming surface;
• and
• a plurality of intermediate sectors carried by the support structure and each having an intermediate forming surface;
• wherein the main sectors and intermediate sectors are alternately arranged around the axis, the main sectors being moveable relative to the support structure between a radially inner main retracted position, and a radially outer main forming position in which each main forming surface defines a part of the cavity profile, and in which the main sectors are spaced apart to define circumferential gaps;
• and
• the intermediate sectors being moveable relative to the support structure between a radially inner intermediate retracted position, and a radially outer intermediate forming position in which the intermediate sectors extend into the respective gaps, and in which each intermediate forming surface defines a part of the cavity profile;
• the mandrel further comprising a drive device for moving the main sectors and intermediate sectors from their respective retracted positions to their respective forming positions;
• wherein the drive device comprises a plurality of drive units, each drive unit being arranged to move at least one of a main sectors and an adjacent intermediate sector from their retracted positions to their forming positions and is configured such that each main sector reaches its main forming position before the adjacent intermediate sectors reach their respective intermediate forming positions;
• wherein a lost motion connection is provided between each drive unit and the respective main sector;
• and
• a winding device arranged to rotate the mandrels simultaneously around their respective axes, each mandrel extending outwardly from the winding device.

A method of forming a component with a cavity using a mandrel having a longitudinal axis and defining a cavity profile, the mandrel comprising:

• a support structure;
• a plurality of main sectors carried by the support structure and each having a main forming surface;
• and
• a plurality of intermediate sectors carried by the support structure and each having an intermediate forming surface;
• wherein the main sectors and intermediate sectors are alternately arranged around the axis, the main sectors being moveable relative to the support structure between a radially inner main retracted position, and a radially outer main forming position in which each main forming surface defines a part of the cavity profile, and in which the main sectors are spaced apart to define circumferential gaps;
• and
• the intermediate sectors being moveable relative to the support structure between a radially inner intermediate retracted position, and a radially outer intermediate forming position in which the intermediate sectors extend into the respective gaps, and in which each intermediate forming surface defines a part of the cavity profile;
• the mandrel further comprising a drive device for moving the main sectors and intermediate sectors from their respective retracted positions to their respective forming positions;
• wherein the drive device comprises a plurality of drive units, each drive unit being arranged to move at least one of a main sectors and an adjacent intermediate sector from their retracted positions to their forming positions and is configured such that each main sector reaches its main forming position before the adjacent intermediate sectors reach their respective intermediate forming positions;
• wherein a lost motion connection is provided between each drive unit and the respective main sector, the method comprising:
• actuating the drive device to move the main sectors to their main forming positions and the intermediate sectors to their intermediate forming positions, each main sector reaching its main forming position before the adjacent intermediate sectors reach their respective intermediate forming positions;
• forming a component on the mandrel;
• actuating the drive device to move the main sectors to their main retracted positions and the intermediate sectors to their intermediate retracted positions;
• and
• removing the component from the mandrel.