CASE STUDY OF CONTOURED TAPE LAYING FOR PRODUCTION

Various aspects of composite part fabrication have been automated in an effort to secure a cost advantage for composite aircraft parts over their metal equivalents. Tape laying of unidirectional composite tape on flat surfaces was one of the first automation efforts. Since its inception in the late 1960’s many advancements have been made in tape laying to the point that it is now possible to lay tape directly on complex contoured tools. Bell Helicopter has continued to explore and push the limits of this technology with the purchase of Ingersoll’s first ± 30 degree contour tape layer. This paper will discuss the steps that Bell Helicopter has taken to establish the constraints of the machine and to minimize the effects of tool curvature and ply buildups throughout the part The areas discussed will include; overall part and tool design constraints (laps/gaps, ramp angles, etc.), the role of the part programming software, quality assurance consideration for inspection acceptance, the effect of caul plates, and bagging materials and procedures.