Curved Mandrels


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remmie
remmie
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Hi,

Looking for advice and thoughts; I'm looking to create a quarter circle tube, approx 1.3m diameter, 18ID, 20OD.  Problem is it needs to be a fairly accurate circle as 4 pieces will be joined to make a ring (demountable prop guard ring for a drone).

At the moment I'm thinking getting a mandrel made from aluminium tube; take it to metal workers and get them to bend me a 120 degree circle.  My concern is would I be able to break the part from the mandrel even if it was a perfect curve without being able to apply any torque to it.  Would I need to step down a size and apply a thin wall silicon tube to it to break away cleanly and handle any deviations in the curve?

Layup schedule will be CF uni, 45/45 CF braided sleeve, 300g Eglass sleeve (need colour and want some sacrificial body), heat shrink tube for compression.   The completed ring needs to make a decent effort of surviving 6kg of force slammed into the ground at decent speeds.

Thoughts, comments, suggestions?

Regards,

Jock
f1rob
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Has your A surface got to be on the inside ? if not female split mould and internal bag would be my route

Thou it somewhat depends on how you plan to join your quarters ? (I would go for male an female step joins one of each on every part

If you have to have A surface on the inside I would say getting a part off in one would be difficult ? can you do each quarter in two goes ? lay up to the centre line of the circle+ 10mm, trim once cured then release if wet lay or cover with PTFE tape if pre preg then lay up the second half of the mould going over your 1st laminate 20mm so your 10mm past the centre line again

Once cured strip both parts (with only 10mm past the centre line parts will have enough flex to be demoulded) abrade your joggle and bond quarters together

Depending on cost/material there is always soluable wash out cores

Or if your doing wet lay mould your own foam cores in quarters or halfs in A+B foam ,lay up over them and then get a bit brutal on the A+B with a chisel once the laminate is cured
remmie
remmie
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Hi,

By 'A' surface are you talking about atheistic or consistent OD/ID? My composite experience comes from boat building, CF is about strength/weight... not look!! Smile 

The quarter joins I was thinking male plug (aluminium insert or CF plug with an ali sleeve) on one end to ensure OD plug matches the ID of the main tube (as ID would be consistent, reverse the idea for a female mould).  There's going to be inward struts for motor mounts and hub join (think wagon wheel) from mid point of each quarter, so it doesn't need to be perfect joint, a bit of movement is fine, it's more as a propellor (anything the propellor could hit) protector.

What do you suggest for split mould technique.... I've seen the technique but never found details on what to use for internal pressure bag?  Assuming it would get killed with each cast so what's cheap and effective?

Been thinking over wash out cores (or even just CNC'ed foam male plug) but obvious fail for repeat performances.

Cheers,

J
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