Innovative tooling concepts for cocured composite structures in aircraft applications

Abstract

Cocuring process is a unique characteristic of composite materials wherein multiple parts like stringers, ribs and spars are simultaneously cured and bonded to a composite skin resulting in an integral structure. It has many benefits like reduction in part count, elimination of stress concentration due to fastener holes in the cocured regions and reduced assembly time and related costs. However, the application of cocuring has been limited on contoured components because of the complexities associated with the tooling. The basic requirements to be fulfilled are (a) consolidation of skins and stiffeners and (b) dimensional tolerance on position and thickness of stiffeners. Proper consolidation can be ensured through the faithful transfer of autoclave pressure by designing tools which are flexible so that they conform to desired shape whereas the positional tolerance can be achieved by using rigid tools. The resolution of such conflicting requirements requires a detailed study of the geometry of the part, design requirements and tolerances achievable on tools. This paper discusses design of tools for two types of cocured structures viz., open and closed cocured structures. The tooling technologies for realising above structures differ considerably. A few tooling concepts have been discussed based on the authors’ experience of developing cocured structures over the last two decades.