SAMPE Journal - November/December 2016 - 12
Feature Article
Figure 11. Simple Springback fixture and coupon. dq is the
change in angle from the 90° of the model during cure and
postcure.
Design Considerations for Common Features
Tooling Bushings / Inserts
The use of inserts in a composite tool is a necessity
with almost every tool in service; they provide location
points, drilling points, multi-piece tool assembly and
inspection location ball placement. As such inserts
require careful consideration at the model and tool
planning stage and just as important are the laminating
methods to incorporate these dissimilar CTE materials to
12
avoid subsequent issues with thermal cycles. In fact, one
of the dominant reasons for composite tool face leakage
relates to poor laminating methodology around inserts,
lack of consideration for matrix exotherm characteristics
(excessive local ply build up to accommodate insert) or
inappropriate choice of insert to be incorporated (poor
size / overall shape).
With a conventional continuous fiber tool the use of a
pre-encapsulated bushing block is often used, this block
contains the desired insert and a 45° chamfered edge to
facilitate laminating into the tool. In Figure 14 the insert
(encapsulated and pre-cured into a prepreg block) is
laminated into the tool by placement on a prepreg pad,
the entire block is then laminated into the tool.
The DForm® tile layup should use the same methods
for inclusion of inserts as continuous fiber tools, with
the exception the cutting and tailoring is completely
eliminated when forming the material over the
encapsulated insert. An example of how an insert might
be included using DForm® tiles is detailed step by step
in Figure 15. The element that is missing when using
DForm® tiles to build a tool is the prepreg to manufacture
the pad shown in Figure 15 which can be taken from a
DForm® tile. This material provides padding and minor
shimming for the pre-encapsulated insert block prior to
laminating.
SAMPE Journal, Volume 52, No. 6, November/December 2016
http://www.expanded-materials.com
http://b.macdonald@dexmet.com
http://www.torrtech.com
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2016
Contents
SAMPE Journal - November/December 2016 - Cover1
SAMPE Journal - November/December 2016 - Cover2
SAMPE Journal - November/December 2016 - Contents
SAMPE Journal - November/December 2016 - 2
SAMPE Journal - November/December 2016 - 3
SAMPE Journal - November/December 2016 - 4
SAMPE Journal - November/December 2016 - 5
SAMPE Journal - November/December 2016 - 6
SAMPE Journal - November/December 2016 - 7
SAMPE Journal - November/December 2016 - 8
SAMPE Journal - November/December 2016 - 9
SAMPE Journal - November/December 2016 - 10
SAMPE Journal - November/December 2016 - 11
SAMPE Journal - November/December 2016 - 12
SAMPE Journal - November/December 2016 - 13
SAMPE Journal - November/December 2016 - 14
SAMPE Journal - November/December 2016 - 15
SAMPE Journal - November/December 2016 - 16
SAMPE Journal - November/December 2016 - 17
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SAMPE Journal - November/December 2016 - Cover3
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