The Boeing Company

Spirit Aerosystems, Inc.

Bradley J Blonigen

William Tod Ross

George M Osborne

Jack Hearnen

Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.

Methods of fabricating multi-region U-shaped composite structures

A method of shaping a layer of settable material such as honeycomb core (24) including placing the core on a flexible support (38); translating the flexible support (38) and core into an oven (28); heating the core to a desired forming temperature in the oven; translating the flexible support (38) and core (24) horizontally from the oven into a forming area (26); lowering a contoured upper die (32) onto the core (24); tensioning the flexible support (38); pressing the core between the tensioned flexible support and the upper die so that the core (24) is forced to conform to the shape of the die (32); cooling the core to set temperature; and raising the die (32) to remove the finished shaped core, is provided. Additionally, a shaping apparatus (22) located in a forming area (26) adjacent an oven (28), for shaping a settable material such as honeycomb core (24) is provided, including: an upper die (32); first and second tensioning assemblies (70), (72) each including a torque supply system; first and second guide assemblies (50), (52) for translating the tensioning assemblies into and out of the oven (28); at least one flexible support (38) wrapped around and between the tensioning assemblies (70), (72) upon which the core may be placed; a regulation system for equalizing tension about the core during pressing; and optional support rollers (166) for focusing the flexible support (38) against the upper die (32) during pressing. A tensioning assembly including a roller (76) and a torque supply system having an air motor (84), is provided. Alternatively, a tensioning assembly including a number of short rollers (92) each powered by a torque supply system having an air motor (108); and a like number of tensioning sub-assemblies (90) each having multiple flexible belts (96) attached thereto, is provided.

Method for shaping honeycomb core

A process of forming and shaping a preheated workpiece made of honeycomb core material using a press including complementary male and female dies. The first step of the process is providing a carrier sheet for supporting the workpiece. The carrier sheet is suspended over the female die by two shafts supported by support towers. The next step is loading the preheated workpiece onto the carrier sheet. The next step is applying rotational torque to each of the two shafts whereby the carrier sheet is wrapped around the said shafts thereby applying tension to the carrier sheet and pulling the shafts toward each other and into pressing contact with the sides of the workpiece while said carrier sheet means supports the bottom surface of said workpiece. The next step is closing the male die and the female die against the workpiece while maintaining the shafts in pressing contact with the sides of the workpiece and while the carrier sheet supports the bottom surface of the workpiece, whereby the workpiece is formed and shaped by the complementary male and female dies into a formed workpiece of the desired shape. The final step is opening the male and female dies and removing the formed workpiece.

Honeycomb core forming process

Apparatus for shaping honeycomb core

A portable version of a honeycomb core forming restricter (20) for forming and shaping a workpiece made of stiff honeycomb core material, the apparatus (20) to be used in combination with a press including a male die (70) and a female die (72), the apparatus (20) including: (a) a base plate (62); (b) four support tower assemblies (24a, 24b, 24c, 24d) supported by the base plate (62); (c) two shafts (22a, 22b) supported by the support tower assemblies (24a, 24b, 24c, 24d), the shafts (2a, 22b) being arranged in a generally parallel relationship to each other and to the longitudinal axis of the female die 72; (d) a carrier sheet (74) for supporting the workpiece, the carrier sheet (74) being attached to the two shafts (22a, 22b); (e) four air motors (26a, 26b, 26c, 26d) for applying rotational torque to the shafts ( 22a, 22b); and (f) the support tower assemblies including a double acting air cylinder (36a) for moving the shaft (22a) in a transverse direction with respect to the longitudinal axis of the female die (72) and a pivoting mount (48a) for allowing the centerpoint of the shaft (22a) to move in an arc in a plane transverse to the longitudinal axis of the female die (72). A dedicated version of the honeycomb core forming restricter is also disclosed.

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Wichita, KS, United States of America

Bradley J Blonigen