A METHOD AND APPARATUS FOR FORMING A COMPOSITE COMPONENT

1 . A method of forming a composite component having a curved body and an integral flange from a pre-form using forming apparatus comprising:

a tool comprising a curved body portion having a lay-up surface and a forming assembly comprising a plurality of forming elements each having a lay-up surface and a primary flange-forming surface; and a plurality of filler elements each having a secondary flange-forming surface;

the method comprising:

providing a pre-form over the lay-up surfaces of the curved body portion and the forming elements of the tool in a layup configuration of the forming assembly;

moving the forming elements radially outwardly from the layup configuration to respective forming positions so that the forming elements are circumferentially spaced apart from one another to form gaps therebetween;

moving the filler elements radially outwardly to respective forming positions in the circumferential gaps between the forming elements so that the primary and secondary flange-forming surfaces form a substantially continuous flange-forming surface in a forming configuration of the forming assembly;

wherein movement of the forming assembly from the layup configuration to the forming configuration causes a region of the pre-form to deform between the continuous flange-forming surface and a counteracting forming surface to form the integral flange of the component.

2 . A method according to claim 1 , wherein the forming elements reach the respective forming positions before the filler elements reach the respective forming positions.

3 . A method according to claim 1 , further comprising providing the tool in the layup configuration so that the lay-up surfaces of the curved body portion and the forming elements are substantially continuous.

4 . A method according to claim 1 , further comprising laying-up the pre-form on the tool in the layup configuration.

5 . A method according to claim 1 , further comprising providing a counteracting support, and wherein the counteracting support defines the counteracting forming surface.

6 . A method according to claim 1 , wherein the forming elements and filler elements are moved simultaneously.

7 . A method according to claim 1 , further comprising heating the tool before moving the forming elements and filler elements from the layup configuration to the forming configuration.

8 . A method according to claim 7 , wherein the tool is heated after the pre-form is laid up on the tool.

9 . A method according to claim 1 , wherein the component is annular or semi-annular.

10 . A method according to claim 1 , wherein the component is a casing for a gas-turbine engine.

11 . A method according to any preceding claim, wherein the tool or forming apparatus is in accordance with claim 12 .

12 . A tool for forming a composite component having a curved body and an integral flange from a pre-form, the tool comprising:

a curved body portion having a lay-up surface; and

a forming assembly having a lay-up configuration and a forming configuration, the forming assembly comprising:

a plurality of forming elements each having a lay-up surface and a primary flange-forming surface, the forming elements being radially outwardly moveable from the lay-up configuration to the forming configuration, in which the forming elements are circumferentially spaced from one another;

a plurality of filler elements each having a secondary flange-forming surface, the filler elements being arranged to move into the circumferential gaps between the forming elements in the forming configuration so as to form a substantially continuous flange-forming surface; and

wherein in use a pre-form is disposed on the layup surfaces of the curved body portion and the forming elements in the layup configuration, and wherein movement to the forming configuration causes the pre-form to be deformed between the continuous flange-forming surface and a counteracting forming surface to form the integral flange.

13 . A tool according to claim 12 , wherein the layup surface of the curved body portion is substantially continuous with the layup surfaces of the forming elements in the layup configuration.

14 . A tool according to claim 12 , wherein the layup surface of the curved body portion is radially spaced apart from the layup surfaces of the forming elements in the layup configuration.

15 . A tool according to claim 12 , wherein the primary and secondary flange-forming surfaces extend at least partly radially.

16 . A tool according to claim 12 , wherein the forming elements and the filler elements are alternately arranged.

17 . A tool according to claim 12 , further comprising a drive means for moving the forming assembly from the lay-up configuration to the forming configuration, the drive means comprising a plurality of drive units, each drive unit being arranged to move at least one forming element;

wherein each drive unit is configured to move the or each respective forming element and an adjacent filler element from respective retracted positions corresponding to the lay-up configuration to respective extended positions corresponding to the forming configuration;

wherein each drive unit is configured so that the respective filler element reaches its respective forming position after the forming element reaches its respective forming position; and

wherein a lost motion connection is provided between each drive unit and the respective forming element.

18 . A tool according to claim 12 , wherein the tool is for forming an annular or semi-annular component.

19 . A tool according to claim 12 , wherein the tool is for forming a casing for a gas-turbine engine.

20 . Forming apparatus for forming a composite component having a curved body and an integral flange, the apparatus comprising:

a tool in accordance with claim 12 ; and

a counteracting support detachably attachable to the tool over a pre-form received on the tool, the counteracting support having a counteracting forming surface arranged to oppose the flange-forming surfaces of the forming assembly so that in use a region of the pre-form is deformed between the forming assembly and the counteracting support to form the flange of the component.