Compacting uncured composite members on contoured mandrel surfaces

1. A method of compacting an uncured composite member against a mandrel surface having a longitudinal contour and curing, comprising:

adhering the uncured composite member to a flexible elongate compactor using a suction force;

using the compactor to align the uncured composite member with the longitudinal contour of the mandrel surface;

using the compactor to bring the uncured composite member initially into contact with the mandrel surface at an apex of the longitudinal contour;

forming the uncured composite member over the contour of the mandrel surface outwardly from the apex;

using the compactor to compact the uncured composite member against the mandrel surface; and

curing the uncured composite member between the mandrel surface and the compactor.

2. The method of claim 1 , further comprising:

distributing any wrinkles that form in the uncured composite member during the forming by allowing material in the uncured composite member to become compressed into kerfs in the compactor.

3. The method of claim 1 , wherein the uncured composite member has a neutral axis and the method further comprises:

using the compactor to reduce wrinkling of the uncured composite member during forming by shifting the location of the neutral axis of the uncured composite member.

4. The method of claim 1 , wherein forming the uncured composite member includes using the compactor to form a twist into the uncured composite member.

5. The method of claim 1 , wherein forming the uncured composite member is performed by drape forming the uncured composite member onto the mandrel surface.

6. The method of claim 5 , wherein the drape forming includes maintaining a substantially constant relationship between ends of the uncured composite member and the mandrel surface as the uncured composite member is being formed onto the mandrel surface.

7. The method of claim 1 , wherein forming the uncured composite member is performed by lash forming.

8. The method of claim 7 , wherein the lash forming includes reducing localized compressive forces in the uncured composite member adjacent the mandrel surface by inducing an S-shaped bend into the uncured composite member.

9. The method of claim 1 , wherein:

the uncured composite member has a preselected positional attitude when it is brought into initial contact with the mandrel surface at the apex, and

the positional attitude of outer sections of the uncured composite member are maintained substantially parallel to the preselected positional attitude as the uncured composite member is being formed over the contour of the mandrel surface.

10. The method of claim 1 , wherein forming the uncured composite member includes bending the uncured composite member to a progressively smaller radius of curvature.

11. A method of controlling wrinkling of an uncured composite member during forming of a composite stringer over a longitudinal contour of a mandrel surface and curing, comprising:

installing a flexible elongate compactor within the uncured composite member;

adhering the uncured composite member to the compactor using a suction force;

aligning the uncured composite member with an apex of the longitudinal contour of the mandrel surface; and,

bringing the uncured composite member initially into contact with the mandrel surface at the apex using the compactor;

forming the uncured composite member from the apex down onto the mandrel surface using the compactor to form an uncured composite stringer; and

curing the uncured composite stringer between the compactor and mandrel surface.

12. The method of claim 11 , wherein forming the uncured composite member from the apex includes bending the uncured composite member down against the mandrel surface and progressively outwardly from the apex.

13. The method of claim 11 , wherein forming the uncured composite member from the apex includes maintaining a substantially constant relationship between ends of the uncured composite member and the mandrel surface.

14. The method of claim 11 , wherein forming the uncured composite member is performed by one of drape forming and lash forming.

15. The method of claim 11 , wherein:

wrinkling of the uncured composite member is controlled by allowing material of the uncured composite member to be compressed into the compactor.

16. The method of claim 11 , wherein:

forming the uncured composite member from the apex down onto the mandrel surface is performed using a compactor, and

the compactor is used to encourage substantially uniform distribution of wrinkles in the uncured composite-member.

17. A method of forming an uncured composite member into a contoured groove in a cure tool and curing, comprising:

adhering the uncured composite member to a flexible elongate compactor using a suction force;

using the compactor to bring the uncured composite member into initial contact with the cure tool at an apex of a longitudinal contour along the contoured groove;

using the compactor to form the uncured composite member down into and along the contoured groove and progressively outwardly from the apex;

using the compactor to distribute wrinkles formed in the uncured composite member during forming of the uncured composite member down into and along the contoured groove; and

curing the uncured composite member between the cure tool and the compactor.

18. The method of claim 17 , wherein using the compactor to form the uncured composite member is performed by one of drape forming and lash forming.