| 摘要 |
A method of forming composite sine wave spars from composite material. In accordance with the method, the sine wave spar is formed of web plies, filler plies, separator plies and cap plies. The edges of the web plies are cut to form a plurality of teeth having different geometric configurations. The web plies are first formed to the sine wave contours of a tool having the desired final part geometry. The teeth of the web plies are then folded over the edges of the tool to form a portion of the flanges of upper and lower U-shaped channels. The portions of the flanges of the U-shaped channels not covered by the teeth are formed using filler plies that intermesh with the teeth to form a layer of the flanges of the respective upper or lower U-shaped channel. The flanges are reinforced through the use of separator plies that are placed between the filler plies. The formed upper and lower U-shaped channels are joined together so that their respective flanges are located in line with each other. The triangular recesses between the flanges of the joined upper and lower U-shaped channels are filled with radius fillers having a triangular cross-section. Once the radius fillers are in place, cap plies are placed over the radius fillers and flanges to further reinforce the flanges. In the preferred embodiment, each web ply has eight different teeth configurations. The teeth are configured to fold over the edges of the sine wave contour and cover the edges of the sine wave contour in order to minimize overlapping and gaps between the folded over teeth. |
