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Home > Science, Technology & Agriculture > Industrial chemistry and manufacturing technologies > Tooling for Composite Parts & Assemblies
Tooling for Composite Parts & Assemblies

Tooling for Composite Parts & Assemblies


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About the Book

Written to be used as both a student reference and a practical manufacturing guide. The proposed book explains the methods of tooling for composites manufacturing, along with approaches for selecting and applying the methods. The book discusses different composite designs and relates this information to fabrication technologies and their associated types of tooling. The text lays out the advantages and disadvantages of tooling strategies and clarifies the risks associated with each. Included are numerous examples, as well as troubleshooting guidelines.

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


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Product Details
  • ISBN-13: 9781605956817
  • Publisher: DEStech Publications, Inc
  • Publisher Imprint: DEStech Publications, Inc
  • Height: 229 mm
  • No of Pages: 410
  • Width: 152 mm
  • ISBN-10: 1605956813
  • Publisher Date: 31 May 2023
  • Binding: Hardback
  • Language: English
  • Weight: 363 gr


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