SAMPE Journal - November/December 2021 - 44
FEATURE / LARGE COMPOSITE AEROSTRUCTURES
added on the top flange of the tool halves (four
total). During fabrication, plates stamped with the
actual center locations of these bushings would be
adhered to the tool to aid in tool alignment during
part lay-up, as well as serve as pick-up points for
confirming tool CTE.
Fabrication
The full-scale tool core was printed in two pieces,
split at roughly the midspan, to accommodate
print height restrictions on the BAAM printer. The
left and right half was combined into a single print
for each of the two pieces to allow for more efficient
printing. The two pieces were bonded together
with Loctite EA9394 and clamped together with
pipe clamps prior to cutting out the left and right
halves (Figure 9). After the adhesive had set at
room temperature, the left and right halves were
cut apart to accommodate for the parting line on
the final tool.
The two tool halves were scanned and the
surfaces were compared to CAD to confirm that
the 3D structures hadn't sprung out of shape when
cut out of the main structure. Both tool halves
showed isolated areas of excessive movement.
These areas were locally heated with a heat gun
and manipulated so that they better conformed to
the original design intent.
The two halves were laid up with Hextool
prepreg, with a slight modification from the
subscale tool. The prepreg was redistributed so
that four plies were added to the backside and 10
plies were added to the topside (layup side). In
addition, an extra strip of prepreg was added on
all male radii. These two modifications allowed for
more face sheet thickness on the tool surface for
machining. As before, hot debulks were done after
plies 1, 4, and 7, and the tool was cured using the
" High Temperature/Standard " cure cycle.
After cure, the tooling surface was machined
to meet geometric tolerance and surface finish
requirements.
RESULTS
Sub-scale Test Results
The completed tool was inspected with a CMM
probe to confirm that the required profile tolerance
was achieved. A machined surface of + / - 0.25 mm
(0.010 " ) from nominal was confirmed on the layup
surface (Figure 10).
In addition to a profile scan, the location of
four pick-up points located in each corner of the
top flanges were measured at room temperature.
After heating the tool to 180°C, these pick-up
point locations were measured again while the
44 | SAMPE JOURNAL | NOVEMBER/DECEMBER 2021
www. sampe.org
C (shown in inches).
Figure 9. Full-scale tool, clamped for bonding. Red line denotes split line,
cut after bonding.
Figure 10. CMM scan map of subscale
tool showing deviation from CAD model
(shown in inches).
Figure 11. Tool expansion as a result of heating from room temperature to
180o
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SAMPE Journal - November/December 2021
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