THE BOEING COMPANY (Chicago, IL)

A tool assembly consists of a first piece, a secondary piece and the fastener. The first piece features one joint that has the top surface and at a minimum, a first interlock surface. The second piece features another joint section that is configured to lock with the first joint part. The second piece of joint has an upper surface as well as at the very least, a second surface that is complementary to the first interlock surface. The fastener is extending between the first and second joint portions. The corner formed by the first interlock surface the top of the first joint section, and the top of the second interlock create an acute angle corner. The first interlock surface is designed to touch the second interlock’s surface to limit the relative movement between the first and second piece along the length-wise axis of this tool assembly.

For large composite parts which are also referred to as work components, like wings, fuselage and other components of aircraft, it is necessary to shape them. can require large tools. These tools include draping instruments as well as support tools, layup surface tools(commonly referred to as molds or mandrels), etc. These tools are utilized in a range of composite part formation techniques, such as hand-layup, automated, draping, hot draping, automated fiber placement as well as automated tape laying curing, and trimming.These tools are made up of surfaces (e.g. the layup surface) which are used to help form or support the formation of the composite parts. Layup surfaces may be geometries, contours, or contours that comply with design specifications. They could also be complementary to the parts that are being made.

Such tools are commonly made from metal and are monolithic pieces (i.e., a single structure composed of multiple permanently joined parts, as with bonded or welded joints). These tools must be precisely contoured, such as within allowable tolerances, and be equipped to withstand the load and strains involved in making the composite part. For example, a particular tool may be subjected to vacuum conditions (e.g., vacuum pressure) and high temperatureconditions during composite formation and curing. A tool that is out of tolerance because of previous use or is unable maintain the vacuum or tolerancing when heated, mass or vacuum needs to be replaced. The process of creating the part can be stopped until new tool becomes accessible. Additionally, at times in a design process, multiple tools designs (e.g. prototype tools or variations of tools) are generated to improvethe manufacturing process of the piece. This is why current tools may have high cost of fabrication and/or long fabrication cycle times.

In a particular implementation the tool assembly comprises the first piece, which has a first joint portion including a top surface and at least a first interlocking surface. The tool assembly also comprises another piece with a second joint portionconfigured to interlock with the first joint portion, the second joint portion having a top surface and at the very least, a second surface that is in a similar manner to the first interlock area. A fastener extends through the first and second joints parts of the tool assembly. The first interlock as well as the top surface of first joint section create an obtuse corner while the second interlock as well as the top surface of the second joint create an acute anglecorner. To avoid any movement between the first and second pieces in the direction of a tool assembly The first interlock is designed so that it will touch the second.

An assembly of tools may comprise a top-surfaced initial piece as well as a portion of the first joint that contains at least one interlock surface. A second piece of the tool assembly has an additional piece with an additional jointportion that is able to be locked with the first piece. The second piece has a top and a minimum an additional interlocking surface. A fastener is inserted between the first and second joint sections of the tool assembly. The first interlock surface and the top surface of the first piece form an obtuse corner. the second interlock surface as well as the top of the second joint portion create an acute anglecorner. The first interlock surface is configured to be in contact with the second interlock’s surface to restrict the movement of the first and second piece along a longitudinal axis of the tool assembly.

A method of heating a tool-assembly includes joining pieces of the first piece to a second piece by using a first and second joint portion. The method also includes inserting a fastener into the first and second joints of the assembly. The method further includes applying heat to the tool assembly and, upon heating the interlocking surfaces of the second and first joint portions become tighter.

In another particular implementation the method of attaching composite material to a tool assembly comprises joining a piece of the tool assembly a second component of the tool assembly by a first joint portion and a third joint portion, in which the tool assembly includes a layup surface. The method also involves the application of the composite material to the surface of the layup. The layup surface is designed to support formation of a composite part and has a shape that is a match to the ashape of the composite piece.

In a different way, a method of creating a tool assembly involves making a first joint from a primary piece of the tool assembly using an additive manufacturing procedure. The first joint part includes a top and at least one interlock surface. A second joint portion is also formed through the process of additive manufacturing. The second joint piece has a top surface and at least a secondinterlock surface that is in a similar manner to the first interlock’s.

By utilizing the tool assembly (e.g., a multi-piece tool) Composite parts can be made faster and at lower cost compared to single piece tools. Furthermore, using the tool assembly that has joint portions and interlock surfaces,the tool assembly can be fabricated to allow the creation of large composite pieces, for example, aircraft wings and fuselage sections.

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