Systems and methods for stretch-forming multi-thickness composite skins

摘要

Systems and methods for stretch-forming multi-thickness composite skins are disclosed herein. The methods include locating a flexible support structure in a transition region that is defined by a charge of composite material and applying a vacuum to an interface between the charge of composite material and the flexible support structure to define a charge-support assembly. The methods also include separating the charge-support assembly from the layup surface and locating the charge-support assembly on a cure surface of a layup mandrel. The methods further include deforming the charge-support assembly on the cure surface to generate a conformed charge of composite material, releasing the vacuum, and separating the flexible support structure from conformed charge of composite material. The systems include systems that are configured to perform the methods.

主权项

1. A method of forming a non-planar skin surface contour of a skin for a composite structure, wherein the skin for the composite structure is formed from a charge of composite material that is defined by a plurality of stacked plies of composite material, wherein the charge of composite material defines a first region that has a first number of stacked plies and a first thickness, and a second region that has a second number of stacked plies and a second thickness that is greater than the first thickness, and further wherein the first region and the second region define a transition region therebetween, the method comprising:
locating a flexible support structure in the transition region such that the charge of composite material extends between the flexible support structure and a layup surface that supports the charge of composite material, wherein the flexible support structure includes a support surface that defines a support surface profile, wherein, prior to the locating the flexible support structure, the charge of composite material defines an exposed surface that defines a non-planar exposed surface profile, wherein the support surface profile corresponds to the non-planar exposed surface profile, and further wherein the locating the flexible support structure includes locating such that the support surface conforms to the exposed surface; applying a vacuum to an interface between the charge of composite material and the flexible support structure to temporarily define a charge-support assembly; during the applying, separating the charge-support assembly from the layup surface; locating the charge-support assembly on a cure surface of a layup mandrel, wherein the cure surface defines a non-planar cure surface contour; deforming the charge-support assembly to conform the charge of composite material to the non-planar cure surface contour and generate a conformed charge of composite material that defines the non-planar skin surface contour; releasing the vacuum; and separating the flexible support structure from the conformed charge of composite material while retaining the conformed charge of composite material on the cure surface.