Dual purpose lay-up tool

Details Dual purpose lay-up tool Dual purpose lay-up tool

1996-04-08

1998-05-05

Howell, Daniel W.

Gear cutting, milling, or planing

Milling

Process

409138, 409197, 409219, 156245, B23C 900

Patent

active

057465533

ABSTRACT:
A method of manufacturing a laid-up, bonded and, cured composite part, includes filling a groove on a facing surface of a tool with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, filling the groove and forming a hard, smooth surface skin on the foam, flush with the facing surface of the tool. A series of plies are laid-up on the facing surface of the tool to form a tool-side skin, and other components of the part are laid-up on top of the tool-side skin plies. An adhesive/resin matrix is coated on or pre-impregnated into the skin plies and the components for bonding/curing to create a rigid integral assembly of the skin and components. A vacuum bag is applied over the laid-up skin and components and is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components. Air is evacuated from under the vacuum bag to cause air pressure outside the vacuum bag to press the vacuum bag against the components. The adhesive/resin matrix is bonded/cured to transform the skin and components into the rigid integral assembly. The vacuum bag is removed from the facing surface of the tool, uncovering the rigid integral assembly. The tool is fixed in a known position on a CNC machine tool bed to position the facing surface of the tool at a known position for edge routing of the rigid integral assembly by a machine tool. A cutter of the machine tool is guided on a predetermined path around the facing surface of the tool, with the cutter extending into the groove below the facing surface of the tool and cutting a peripheral edge around the rigid integral assembly. After edge routing, the rigid integral assembly is a finished part and is removed from the from the facing surface of the tool.

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