Methods and systems for forming curved composite charges for stringers

• Main Authors: Jones, Darrell D, Plummer, Steven J, Willden, Kurtis S, Kendall, James R, Shaw, Paul D, Suriyaarachchi, Raviendra S
• Format: Patent
• Language: English
• Published: 29.03.2022
• Subjects: AEROPLANES; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; AIRCRAFT; AVIATION; COSMONAUTICS; HELICOPTERS; INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULARARTICLES; PERFORMING OPERATIONS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; TRANSPORTING; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

Described are methods and systems for manufacturing curved composite stringers. Such composite stringers may have in-plane and/or out-of-plane bends, which are formed while shaping composite charges. Specifically, a composite charge is shaped using a pallet, comprising a plurality of independent pallet portions, rotatably coupled to each other. A hat portion is formed when a part of this charge is conformed to a cavity in the pallet. The pallet portions are rotated relative to each other while forming the hat portion and/or when the hat portion already conforms to the cavity. In some examples, the die is bent together with the charge, when the pallet portions are rotated. This rotation produces one or more of in-plane and/or out-of-plane bends. In some examples, flange portions of the composite charge are positioned in a temporary orientation, e.g., to enable bending of the charge and reduce wrinkles.