Apparatus for making contoured composite stiffeners

1. Apparatus for making a composite structural member having a web and having at least one contour, comprising:

an assembly tool for assembling a plurality of plies forming a charge, wherein the assembly tool comprises:

an alignment guide having an adjustable contour against which the plies of the charge may be aligned and contoured; and

a spacer adapted to be placed on the charge and having a width substantially equal to a height of the web; and

a forming tool for forming the charge, the forming tool including a pair of relatively movable mandrels between which the assembled charge may be clamped.

2. The apparatus of claim 1 , wherein the assembly tool further includes:

a clamping mechanism for clamping aligned plies together.

3. The apparatus of claim 1 , wherein;

the forming tool includes a substantially vacuum tight base having pass-throughs adapted to receive for vacuum, compressed air and resin lines,

the mandrels are relatively moveable on the base toward and away from each other, and

the mandrels include tool surfaces over which at least a portion of the clamped charge may be formed.

4. The apparatus of claim 1 , wherein the forming tool includes an inflatable bladder for applying clamping pressure to one of the mandrels.

5. The apparatus of claim 1 , further comprising:

a first vacuum bag adapted to cover the formed charge;

a second vacuum bag adapted to cover the formed charge clamped on the forming tool and hold at least a portion of the charge against the tool; and

a resin supply line for introducing resin into the first bag and infusing the charge.

6. The apparatus of claim 1 , wherein each of the mandrels includes a contoured clamping surface for forming a contour into the charge.

7. Apparatus for making a composite member having a web with a compound contour and at least one flange, comprising:

an assembly tool for pre-aligning a charge along a first contour, the assembly tool further comprising:

a surface on which a multi-ply charge may be assembled;

an alignment guide having an adjustable contour against which the plies of the charge may be aligned and contoured;

a spacer adapted to be placed on the charge and having a width substantially equal to a height of the web portion;

at least one clamp for clamping aligned and contoured plies together with the spacer, and

grooves to allow clamping access to both sides of the charge; and

a forming tool including a base and a pair of contoured mandrels on the base between which a web portion of the charge may be clamped and formed along a second contour.

8. The apparatus of claim 7 , wherein at least one of the pair of contoured mandrels includes a tool surface onto which a flange portion of a clamped charge may be formed.

9. Apparatus for making a compound contoured composite stringer for aircraft having a web and a flange, comprising:

an alignment and assembly tool, including—

a flat surface on which a flat charge may be placed,

an alignment fence having a first contour corresponding to one of the contours of the stringer and against which the charge may be aligned,

a web height spacer for establishing the height of the stringer web;

a plurality of clamps for clamping the charge and adapted to abut the web height spacer;

a forming and cure tool, including—

a tool base having a first contour which largely matches the contour of the alignment fence on the assembly tool, the tool base including an assembly of a base plate and spaced apart curved blocks,

a pair of mandrels relatively slideable on the tool base toward and away from each other, the mandrels including a first set of opposing surfaces having a second contour for clamping a web portion of the charge therebetween, the mandrels further including a second set of tool surfaces onto which a flange portion of the charge may be formed;

a first inner bag covering the formed charge;

a second bag covering the charge and the first bag;

first and second seals for sealing the first and second bags to the forming and cure tool;

a resin infusion inlet for allowing resin to flow into the charge within the first bag; and

at least one resin outlet for allowing resin to escape from the charge.