Male Molding Fabrication Process Development with Composite Materials
Open Access
- Author:
- Tachie-menson, Yooku
- Graduate Program:
- Aerospace Engineering
- Degree:
- Master of Science
- Document Type:
- Master Thesis
- Date of Defense:
- December 12, 2012
- Committee Members:
- Dennis K Mclaughlin, Thesis Advisor/Co-Advisor
Thomas David Juska, Thesis Advisor/Co-Advisor
George A Lesieutre, Thesis Advisor/Co-Advisor - Keywords:
- debulk
spar
composite
materials
caul
male molding - Abstract:
- Processes used to fabricate thick composite beams were developed. The advantage of female molding, which is typically used, is that it provides a smooth outer molded surface. However, the lay-up process is labor intensive, and the two halves need to be joined in a secondary operation. Male molding is generally less labor intensive, and allows the beam to be fabricated as a single part, thus eliminates the need to join separately fabricated sections. In the work described herein, a male molding beam fabrication process was developed that results in a smooth outer surface. This was achieved through the use of caul (external) tooling. De-bulk cycles were used to consolidate the laminate and reduce the degree of wrinkling on the surface of the male molded part. This paper also provides examples of innovative methods currently and formerly used in industry to both contrast and compare the methods to be used during experimentation. Trials were done on a tapered male foam mandrel using lay-ups of 10 ply increments (about 0.25” thick). About 100 plys of composite prepreg material were used during the process trials, which involved innovative in-situ gap fillers implemented between caul sections. In this way, the entire surface can be tooled. It was found that this was necessary to eliminate the occurrence of wrinkles and ridges during de-bulk of the laminate. Results showed that thick beams can be male molded to achieve a smooth outer surface with the use of corner and flat caul blocks accompanied by in-situ caul gap fillers.