Engineering Professional Programs

Course Outline

Tooling Module

1. Introduction and Background

1.1 The Functionality of & Requirements for LMs

1.2 Developing a Tooling Concept

1.3 Terminology

1.4 The Autoclave Environment and its Effects - Temperature & Pressure

1.5 Tooling Materials

1.6 General Design Considerations

2. Metal Panel Layup Tooling (Tools made of Invar, Steel, etc.)

2.1 Invar Materials and Invar Tooling Fabrication Processes

2.2 Other Historical Tooling Materials - Aluminum, Steel and Nickel

2.3 Thermal Correction Factors

2.4 Castings

2.5 Design Criteria and Typical Tool Features

2.6 Eggcrate Design

2.7 Tool Repairs

2.8 Multi-stage/Multi-Purpose Tools - Bond Assembly Jigs and Tools with Trim/Drill Features

2.9 General Design Considerations

3. Composite Panel Layup Tooling (Tools made of composite materials)

3.1 Material Selection Criteria

3.2 Design Criteria and Typical Tool Features

3.3 Tool Coordination

3.4 Tool Face Sheet Fabrication Methods

3.5 Substructure Design Alternatives

3.6 Eggcrate Substructure Design

3.7 Tool Failure Modes

3.8 Composite Tooling Materials and Sources

3.9 Part Models

4. Layup Tools used for Automated Layup (Automated Fiber Placement and Automated Tape Laying)

4.1 Unique Design Requirements

4.2 Tool / Machine Interface Requirements

4.3 Seals

4.4 Tool Assembly/Disassembly

4.5 Caul Sheets

5. Layup Tools for Internal Composite Structural Parts

5.1 General Design Considerations

5.2 Tool/Part Orientation

5.3 Tool Mistake-proofing

5.4 Tool Removal for "Locked" Tools

5.5 Index Pins

5.6 Rib and Spar Tools

5.7 Resin Transfer Molds and Related Tools

5.8 Molds for Thermoplastic Reinforced Thermoplastic Molding (RTL)

6. Layup Tools for Dealing with Trapped Volume Conditions

6.1 General Design Considerations

6.2 Bladders

6.3 Plaster Mandrels

6.4 Salt Mandrels

6.5 Reconfigurable Mandrels

6.6 "Fly Away" Tools

6.7 Segmented Tools

6.8 Rubber/Elastomeric-Faced Tools

7. Interiors Tooling

7.1 Interiors-Unique Processes

7.2 Compression Molds

7.3 Mold Die Design Requirements

7.4 Typical Features

7.5 Vacuum Form Molds

7.6 VFM Design Requirements

7.7 Typical Features

7.8 Interiors Assembly Operations

8. Trim Tooling for Composite Parts

8.1 General Design Considerations

8.2 Hand Router Fixtures

8.3 Shaper Fixtures

8.4 NC Mill Fixtures for Laminated Parts

8.5 NC Mill Fixtures for Core Details or Subassemblies

8.6 Universal Holding Fixtures

9. Assembly Tooling for Composite Structural Assemblies

9.1 Assembly Basics - Indexing, Clamping, Fasteners, etc.

9.2 Removable Tool Parts

9.3 Determinant Assembly vs Tooled Assembly

9.4 Reference Systems and Computer-Aided Measurement Systems (CAMS)

9.5 Applied Drilling Tools

9.6 Applied Locating Tools

9.7 Portable Tools - Drilling Equipment

9.8 Drilling Setup Sheets

9.9 Scaffolding and Floor Mounted Equipment

10. Handling Equipment for Composite Parts and Assemblies

10.1 General Design Considerations

10.2 What's Different for Handling Composite Parts

10.3 Protective Equipment

10.4 Transportation Dollies

10.5 Overhead Handling

10.6 Shipping Equipment

11. Module Review & Wrap-up

Mid-term and Evaluation

Instructors

Tooling: Prof. M. Ramulu and Mr. David Dickson
Repair: Prof. Brian Flinn and Dr. Gary Oakes

Questions

If you have questions about this program, please call UW Educational Outreach Advising at 206-685-8936 in the greater Seattle area or 1-800-543-2320. If you have questions about registration for this program, please call the UW Educational Outreach Registration Department at 206-543-2310 or 1-800-543-2320.

For more information about Boeing initiatives in composites education,email Michael Richey, Boeing Learning Training and Development, Engineering & Operations Group.