Tooling for Composite Parts & Assemblies

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. Invalite^TM Invar Face Sheet with CFRP Eggcrate
6.4. Carbovar^TM Plated Facesheet with Conventional CFRP Eggcrate
6.5. HyVarC^TM 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 PTFS^TM System
7.7. Isobar^TM 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