Tooling for Composite Parts & Assemblies

Table of Contents:
Chapter 1. Introduction to Composite Materials and Composites Manufacturing 1.1. Introduction 1.2. Composite Materials—Resins and Fibers 1.3. High-Level View of Aerospace Composites Design and Fabrication 1.4. Alternative Aerospace Layup and Cure Processes 1.5. Typical Equipment for Composites Facilities 1.6. Chapter Summary 1.7. Chapter 1 Review Questions Chapter 2. Introduction to Layup Tooling 2.1. Introduction 2.2. Manufacturing Differences between Aluminum Airplane Parts and Composite Parts 2.3. Cure Temperature and Tool Thermal Expansion 2.4. Part Anomalies Caused by Tool Thermal Growth 2.5. Other Part Anomalies 2.6. Heat Transfer 2.7. Dealing with Autoclave Pressure 2.8. Dealing with Resins and Chemicals 2.9. Chapter Summary 2.10. Chapter 2 Review Questions Chapter 3. Designing Tools for Composite Layup and Cure 3.1. Introduction 3.2. Aircraft Structure and Various Types of Molds 3.3. Requirements for Layup Tooling (Molds) and Developing a Concept 3.4. Stress Analysis Requirements 3.5. Designing Tools Used with Automated Layup Equipment 3.6. Chapter Summary 3.7. Chapter 3 Review Questions Chapter 4. Panel Layup Tools: Metal Tooling Materials 4.1. Introduction 4.2. Metal Tooling Materials 4.3. Tool Architecture 4.4. The Advent of Invar as a Tooling Material 4.5. Invar Alloy Specifications 4.6. Fabrication Methods for Eggcrate/Panel-Type Tools 4.7. Dealing with Extremely Large Tools 4.8. Invar Castings for Tooling 4.9. Cost of Invar Panel Tooling 4.10. Nickel Shell Molds 4.11. Tool Repairs 4.12. Chapter Summary 4.13. Chapter 4 Review Questions Chapter 5. Panel Tools Made with Composite Materials 5.1. Introduction 5.2. Masters for Composite Molds 5.3. Tool Families 5.4. Tool-to-Tool Coordination 5.5. Transfer Tolerances 5.6. Composite Tooling Materials 5.7. Important Considerations for Tooling Materials 5.8. Face Sheet 5.9. Tool Fabrication—How the Mold Comes Together 5.10. Chapter Summary 5.11. Chapter 5 Review Questions Chapter 6. CFRP/Invar Hybrid Molds 6.1. Introduction 6.2. The "Old School" Approach—Conventional CFRP Face Sheet with Invar Eggcrate 6.3. InvaliteTM Invar Face Sheet with CFRP Eggcrate 6.4. CarbovarTM Plated Facesheet with Conventional CFRP Eggcrate 6.5. HyVarCTM Hybrid Invar/Composite Molds 6.6. Molds with Slip Planes 6.7. Chapter Summary 6.8. Chapter 6 Review Questions Chapter 7. Integrally Heated Molds 7.1. Introduction 7.2. Traditional Electrical Heating Methods 7.3. Examples From the Wind Turbine Blade Fabrication Industry 7.4. Liquid Heated Metal Molds 7.5. Heating with Conductive Carbon Foam 7.6. Surface Generation's PTFSTM System 7.7. IsobarTM Heat Pipes 7.8. Chapter Summary 7.9. Chapter 7 Review Questions Chapter 8. Molds for Internal Structure and Closed Molding 8.1. Introduction 8.2. Molds for Wing Stringers 8.3. Fuselage Frame Molds 8.4. Molds for Large Ribs and Spars 8.5. Molds for Small Ribs 8.6. Molds for Tees/Chords 8.7. Resin Transfer Molds 8.8. Molds for Thermoplastic Parts 8.9. Compression and Interiors Molds 8.10. Induction-Heated Molds 8.11. "On-the-Fly" Consolidation 8.12. Chapter Summary 8.13. Chapter 8 Review Questions Chapter 9. Molds and Other Tools Made by Additive Manufacturing 9.1. Introduction 9.2. Machines and Processes 9.3. Post-Processing 9.4. Contoured Surfaces 9.5. Infill 9.6. Bushings in 3D Printing Tools 9.7. Big Tools from (Relatively) Small Machines 9.8. Materials 9.9. Additive Manufacturing Tooling Applications 9.10. Chapter Summary 9.11. Chapter 9 Review Questions Chapter 10. Molds for Trapped Volumes 10.1. Introduction 10.2. Segmented Tools 10.3. Bladders 10.4. Expendable Tools 10.5. Shape Memory Polymer Tools 10.6. Reconfigurable Tools 10.7. Chapter Summary 10.8. Chapter 10 Review Questions Chapter 11. Cauls and Pressure Intensifiers 11.1. Introduction 11.2. A Review of the Issues 11.3. Caul Materials 11.4. Fabrication of Fiberglass Cauls with Room Temp Curing Epoxy 11.5. Fabrication of Carbon Fiber Cauls 11.6. Design Rules for Cauls (With Special Thanks to Kirt Butler of Boeing) 11.7. Pressure Intensifiers 11.8. Chapter Summary 11.9. Chapter 11 Review Questions Chapter 12. Vacuum Bags 12.1. Introduction 12.2. Vacuum Basics 12.3. Traditional Bagging Materials 12.4. The Various Types of Reusable Bags 12.5. Reusable Bags for Large Parts 12.6. Vacuum Leak Detection 12.7. Chapter Summary 12.8. Chapter 12 Review Questions Chapter 13. Molds for Prototyping, Repairs, and the Hobbyist 13.1. Introduction 13.2. Considerations 13.3. Methods 13.4. Molds for Composite Repairs 13.5. Wet Carbon Fiber Layup Molds and Parts 13.6. Chapter Summary 13.7. Chapter 13 Review Questions Chapter 14. Tools for Trimming and Milling Composite Parts 14.1. Introduction 14.2. The Function of Trim Tools 14.3. Tools for Hand Routing 14.4. Tools for Use with a Pin Shaper 14.5. Tools for Trimming and/or Gage Reduction with Automated Equipment 14.6. Universal Holding Fixtures 14.7. Vacuum Chuck-Type NC Mill Fixtures 14.8. Cutters 14.9. Chapter Summary 14.10. Chapter 14 Review Questions Chapter 15. Assembly Tooling 15.1. Introduction 15.2. Assembly 15.3. Bonded Assemblies 15.4. Types of Tools Often Used in Assembly 15.5. Miscellaneous Capital Equipment Used in Assembly 15.6. Drilling for "One-Up" Assembly 15.7. Conventional Drilling 15.8. Fasteners In Composite Structure 15.9. Sealing 15.10. Section Joins and Final Assembly 15.11. Chapter Summary 15.12. Chapter 15 Review Questions Chapter 16. Factory and Equipment 16.1. Introduction 16.2. General Factory Arrangement 16.3. Facilities and Equipment Planning 16.4. Factory Areas 16.5. Composite Equipment 16.6. Chapter Summary 16.7. Chapter 16 Review Questions Chapter 17. Supplier Selection 17.1. Introduction Appendix A: The 7E7 Fuselage Barrel Development Story and Some of the Lessons Appendix B: Tooling Suppliers Appendix C: Tooling Material Suppliers Appendix D: Manufacturers of Equipment for Composite Fabrication Glossary References Index