Mandrel extraction system and method
AssigneeRtx Corporation
InventorsJonathan E. EHEANDER, Jonas BANHOS, James T. ROACH
Life of this patent
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Abstract
Systems and methods are disclosed for producing a hollow composite part, such as a CMC airfoil, using a segmented mandrel formed of individual mandrel segments. The individual mandrel segments may be dimensioned to permit extraction from highly twisted and/or curved parts.
Claims20
A system for producing a curved and/or twisted hollow composite part, comprising:
- a first segment of cavity mandrel configured for a first portion of the composite part, the first segment having a first opening extending therethrough;
- and
- a second segment of cavity mandrel configured for a second portion of the composite part, the second segment having a second opening extending therethrough that is substantially aligned with the first opening,
- wherein the second segment is disposed adjacent to the first segment.
A system for producing a ceramic matrix composite (CMC) airfoil part, the CMC airfoil part having an airfoil cross-section in a first direction and extending in a second direction transverse to the first direction, the system comprising:
- a cavity mandrel dimensioned to form the CMC airfoil part, the cavity mandrel formed of a plurality mandrel segments dividing the cavity mandrel in the first direction and extending in the second direction, wherein each mandrel segment includes:
- a keyway opening extending in the second direction between a distal face and a proximal face;
- a first alignment recess surrounding the keyway opening at the distal face;
- a second alignment recess spaced from the first alignment recess on the distal face;
- a first alignment protrusion surrounding the keyway opening at the proximal face and configured to mate with the first alignment recess;
- a second alignment protrusion spaced from the first alignment protrusion on the proximal face and configured to mate with the second alignment recess,
- wherein:
- a depth of the first alignment recess is greater than a height of the first alignment protrusion to form a gap,
- the keyway is configured for passage of an extraction tool, and
- the gap is configured to permit rotation of a distal end of the extraction tool and provide an extraction surface on the distal face for the distal end of the extraction tool.
A method for producing a hollow composite part, comprising:
- providing a cavity mandrel dimensioned to form the part, the cavity mandrel formed of a plurality mandrel segments dividing the cavity mandrel in a first direction and extending in a second direction transverse to the first direction;
- forming the hollow composite part on the cavity mandrel;
- extracting at least one mandrel segment by:
- inserting an extraction tool from a proximal end into a keyway formed through the mandrel segment in the second direction,
- rotating the extraction tool to engage a distal surface of the mandrel segment extending in the first direction with a distal end of the extraction tool, and
- applying force to the extraction tool in the proximal direction to move the mandrel segment in a proximal direction for extraction from the part.
Dependencies are inferred from the claim text.