METHOD AND APPARATUS FOR FORMING AIRFOIL STRUCTURES

摘要

A fiberglass or other material skin is applied to a composite airfoil structure in a mold assembly having a partially compliant caul plate component which defines the shape of the lower surface of the airfoil. The caul plate component includes a first portion which is essentially rigid and which covers the leading edge of the airfoil. The rigid portion of the caul plate component provides improved conformation of the airfoil skin to the leading edge of the airfoil. The caul plate component also includes a compliant portion which covers and defines the shape of the trailing edge of the lower surface of the airfoil. The stiffness of the caul plate component also has a variable stiffness zone which interconnects the rigid and compliant portions thereof. The use of rigid and compliant portions on the caul plate provides for a controlled conformance of the skin to the leading edge of the airfoil, while allowing the skin to accurately conform to the remainder of the airfoil in spite of variations in the dimensions of internal operating components of the airfoil.