Abstract: A method and apparatus are provided for substantially containing dust generated along a fiber tow path extending from a creel to a compression roller in an automated fiber placement machine, by enclosing substantially all of the path of the fiber tows between the creel and the compression roller within a barrier that is substantially impermeable to dust. A dust collection apparatus may have a porous media and/or utilize an electrostatic charge for entrapping the dust.

Abstract: An apparatus and method are provided for forming a composite part on a tool surface, during an automated fiber placement process, by depositing the composite material onto the tool surface with two or more fiber placement heads which are capable of simultaneous movement independently from each other and the tool surface, but dynamically synchronized for operation with respect to a common time base. Fiber placement heads, and creels for holding composite materials supplied to the fiber placement heads are replaceable during fabrication of the composite part.

Abstract: A method and apparatus are provided, for clamping a fiber placement tool to a fiber placement machine, along a rotational axis of the fiber placement machine, through use of a clamping apparatus having a plurality of drive lugs extending axially from the machine, and having three intersecting faying surfaces thereof which mate simultaneously in substantially intimate contact with three corresponding intersecting faying surfaces of a plurality of drive lug receptacles extending axially from the tool. Pairs of movable tines, disposed on opposite sides of each drive lug, pull the drive lugs into intimate contact with the drive lug receptacles. Master fixtures are used for setting the drive lugs and lug receptacles with respect to corresponding ones of the other, to achieve a desired intimate fit between faying surfaces thereof.

Abstract: An apparatus comprising a fiber placement head assembly and an infrared heating assembly is provided. The fiber placement head assembly includes a compaction roller assembly and a feeder assembly. An infrared heating assembly, a cooling mechanism, temperature sensors, and a controller are operably coupled to the fiber placement head assembly. The infrared heating assembly includes an infrared heater that generates a heating profile. The heating profile defines a heating zone on either a tool or previously laid tows. If the burn point of either the tool or previously laid tows within the heating zone is approached, the controller, which receives temperature readings from the temperature sensors, simultaneously disables the infrared heater and activates the cooling mechanism. As such, the tool and the previously laid tows are protected from being ruined due to an over temperature condition.

Abstract: An apparatus and method are provided for performing, on-the-fly, real time inspection of a composite structure formed by an automated fiber placement machine, through comparison of a visual image of at least a portion of the composite structure to a virtual image of the composite structure. Proper formation of the structure, and/or anomalies within the structure, are determined by comparing the visual image to the virtual image. The automated fiber placement machine, and/or tooling upon which the fiber is placed, are manipulated, and a visual indicator are provided to facilitate inspection and/or repair of any detected anomalies during fabrication of the composite structure.

Abstract: A method and apparatus are provided for adding material to a workpiece mounted on a machine tool, while the workpiece is mounted on a machine tool, by melting a portion of the workpiece, in a zone of addition of the workpiece, using a material addition device including a laser, to form a puddle of molten material of the workpiece in the zone of addition, and feeding the material to be added into the puddle of molten material while continually applying heat with the laser. The melting and feeding are performed while the workpiece remains mounted in the same set-up that is used for machining the workpiece on the machine tool, except for replacing machining cutters used during machining operations with the material addition device. The machine tool may be a lathe, a grinder, a milling machine, a jig bore, or any other type of machine tool.

Abstract: An improved automated method and apparatus are provided for forming composite structures, by calendering two or more elements of a pre-impregnated composite material into a band of uncured composite material, and then forming the uncured band of composite material into one or more formed, uncured composite structures.

Abstract: An apparatus and method are provided for forming a composite part on a tool surface, during an automated fiber placement process, by depositing the composite material onto the tool surface with two or more fiber placement heads which are capable of simultaneous movement independently from each other and the tool surface, but dynamically synchronized for operation with respect to a common time base. Fiber placement heads, and creels for holding composite materials supplied to the fiber placement heads are replaceable during fabrication of the composite part.

Abstract: An apparatus and method are provided for performing a high-speed event, such as a cut/add of a tow, in an automated fiber placement process, by initiating the high-speed event prior to a fiber placement head reaching a location along a tool path of the fiber placement head at which it is desired to have the high-speed event completed.

Abstract: A method and apparatus are provided for forming a composite structure with an automatic placement head, through the use of a non-rotating tooling tablet having first and second substantially oppositely facing surfaces thereof, joined around the peripheries thereof by a side surface of the tablet, with at least one of the first or second surfaces forming a tool surface of the tablet. Layers of pre-impregnated fiber or tape are applied to the tool surface of the tablet by the automated fiber placement head.

Abstract: A milling machine includes a bi-directional, variable speed, rotary workpiece-holding table, a table drive sized to achieve relatively high acceleration and deceleration rates, a cutting tool mounted to a single or dual axis head, and a control system adapted to achieve a high degree of tool position and table rotational position accuracy cooperating to permit high-speed machining operations, including substantially dome-shaped parts characterized by circumferential surface portions interruped by radial wall portions. A dual table drive and interchangeable head arrangement make the machine also suitable for conventional turret lathe operations.

Abstract: A method adapted to achieve a high rate of material removal when, for example, milling a cavity into a work piece. The method includes providing for a cutter path in which the angular engagement between the cutter and the work piece is maintained below a predetermined value to prevent premature wear of the tool, providing for a cutter path which permits a constant cutter feed rate including during directional changes in the path, and machining a series of nested pockets into the work piece utilizing cutter paths as provided for above.

Abstract: A milling machine includes a bi-directional, variable speed, rotary workpiece-holding table, a table drive sized to achieve relatively high acceleration and deceleration rates, a cutting tool mounted to a single or dual axis head, and a control system adapted to achieve a high degree of tool position and table rotational position accuracy cooperating to permit high-speed machining operations, including substantially dome-shaped parts characterized by circumferential surface portions interrupted by radial wall portions. A dual table drive and interchangeable head arrangement make the machine also suitable for conventional turret lathe operations.

Abstract: A milling machine includes a bi-directional, variable speed, rotary workpiece-holding table, a table drive sized to achieve relatively high acceleration and deceleration rates, a cutting tool mounted to a single or dual axis head, and a control system adapted to achieve a high degree of tool position and table rotational position accuracy cooperating to permit high-speed machining operations, including substantially dome-shaped parts characterized by circumferential surface portions interrupted by radial wall portions. A dual table drive and interchangeable head arrangement make the machine also suitable for conventional turret lathe operations.