Compaction pressure distribution and pressure uniformity of segmented rollers for automated fiber placement

2021 ◽  
pp. 073168442110541
Author(s):  
Yuxiao He ◽  
Junxia Jiang ◽  
Weiwei Qu ◽  
Yinglin Ke
Keyword(s):  
Pressure Distribution ◽  
Experimental Validation ◽  
Compaction Pressure ◽  
Single Point ◽  
Fiber Placement ◽  
Point Pressure ◽  
Automated Fiber Placement ◽  
Distribution Limits ◽  
The Relationship ◽  
Single Sequence

For automated fiber placement onto molds with complex surfaces, uneven compaction pressure distribution limits tows number in a single sequence and affects layup quality. Compaction roller has a direct influence on the pressure distribution, but the relationship between the two has not been widely explored. In this paper, the segmented compaction roller is used, and a theoretical model of compaction pressure distribution for layup onto general surfaces is established by analyzing the contact between the roller and prepreg layers, followed by experimental validation. Based on the model, single-point pressure uniformity and whole-path pressure uniformity are proposed to quantitatively evaluate the pressure distribution. Furthermore, pressure distribution and pressure uniformity of segmented roller and common roller are compared, as well as the influence of the two pressure distribution on layup quality. The results show that the established model can predict pressure distribution and provide a basis for analyzing layup defects, and segmented rollers apply evener compaction pressure and help to improve layup quality.

Effects of processing parameters on the performance of carbon fiber reinforced polyphenylene sulfide laminates manufactured by laser-assisted automated fiber placement

2021 ◽  
pp. 002199832110558
Author(s):  
Dacheng Zhao ◽  
Jiping Chen ◽  
Haoxuan Zhang ◽  
Weiping Liu ◽  
Guangquan Yue ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Process Parameters ◽  
Compaction Pressure ◽  
Polyphenylene Sulfide ◽  
Void Content ◽  
Fiber Reinforced ◽  
Tool Temperature ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Carbon Fiber Reinforced

In situ consolidation of thermoplastic composites can be realized through laser-assisted automated fiber placement (AFP) technology, and the properties of composites were significant affected by the process parameters. In this work, the effects of process parameters on the properties of continuous carbon fiber–reinforced polyphenylene sulfide (CF/PPS) composites manufactured by laser-assisted AFP were investigated. Four-plies CF/PPS prepreg was laid under the combination of different process parameters and the morphology, void content, crystallinity, and inter-laminar shear strength (ILSS) of the composites were characterized. It turned out that the resin distribution on the surface of the composites could be significantly improved by increasing the laser temperature and compaction pressure. The highest crystallinity of the composites reached 46% at tool temperature of 120°C while the value was only 18% when the tool temperature was 40°C. Meanwhile, with the increasing compaction force ranging of 500–2000 N, the void content of the composites decreased obviously. The ILSS was evaluated through double notch tensile shear test. The results indicated that the mechanical properties of the composites were dominated by void content rather than crystallinity.

Impact of layup rate on the quality of fiber steering/cut-restart in automated fiber placement processes

2015 ◽  
Vol 22 (2) ◽  
pp. 165-173 ◽  
Author(s):  
Jihua Chen ◽  
Teresa Chen-Keat ◽  
Mehdi Hojjati ◽  
AJ Vallee ◽  
Marc-Andre Octeau ◽  
...  
Keyword(s):  
Compaction Pressure ◽  
Experimental Studies ◽  
Process Condition ◽  
Processing Parameters ◽  
Experimental Results ◽  
High Quality ◽  
Fiber Placement ◽  
Automated Fiber Placement

AbstractDeveloping reliable processes is one of the key elements in producing high-quality composite components using an automated fiber placement (AFP) process. In this study, both simulation and experimental studies were carried out to investigate fiber steering and cut/restart under different processing parameters, such as layup rate and compaction pressure, during the AFP process. First, fiber paths were designed using curved fiber axes with different radii. Fiber placement trials were then conducted to investigate the quality of the steered fiber paths. Furthermore, a series of sinusoidal fiber paths were fiber placed and investigated. Moreover, a six-ply laminate with cut-outs in it was manufactured in the cut/restart trials. The accuracy of the fiber cut/restart was compared at different layup rates for both one- and bi-directional layups. Experimental results show that it was possible to layup steered fiber paths with small radii of curvature (minimum 114 mm) designed for this study when the proper process condition was used. It was observed from the cut/restart trials that the quality of tow cut was independent of layup speed; however, the accuracy of tow restart was related to the layup speed. The faster the layup speed, the less accurate was the tow restart.

Placeability restricted by in-complete contact between laying roller and mould in an automated fiber placement process

2018 ◽  
Vol 37 (7) ◽  
pp. 475-489 ◽  
Author(s):  
Qiyi Chu ◽  
Yong Li ◽  
Jun Xiao ◽  
Dajun Huan ◽  
Xiangyang Zhang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Pressure Distribution ◽  
Quantitative Relationship ◽  
Element Model ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Complete Contact ◽  
Interlayer Bonding ◽  
The Finite Element Model

In this study, the effect of a roller’s deformability on the placeability restricted by an incomplete contact between a laying roller and mould in an automated fiber placement process was analyzed. The incomplete contact phenomenon was defined theoretically through the differential geometry, and corresponding criteria of placeability were proposed by analyzing the mechanism of interlayer bonding. A finite element model was established to simulate the pressure distribution on the contact zone. The pressure measurement of laying on a curved mould was conducted and the infrared thermographic method was utilized to detect the layup defects. The results of the theoretical analysis showed that the criteria of placeability must satisfy complete contact and pressure’s uniformity simultaneously and be implemented in the condition of laying on a cylinder mould with a fixed angle trajectory. The deformability of the roller with different layup forces relates to its material module and its geometry. The finite element model of pressure distribution was verified by an experiment, and the quantitative relationship between the uniformity of pressure and roller’s module, mould’s radius and tows’ width was acquired by this model. With the increase of module and tows’ width, the uniformity decreases; while with the increase of mould’s radius, the uniformity increases. The thermographic results showed that optimized parameters can guarantee the interlaminar bonding to avoid delamination for laying on the curved mould with a restriction of the incomplete contact.

scholarly journals Effect of compaction roller on layup quality and defects formation in automated fiber placement

2019 ◽  
Vol 39 (1-2) ◽  
pp. 3-20 ◽  
Author(s):  
Nima Bakhshi ◽  
Mehdi Hojjati
Keyword(s):  
Experimental Study ◽  
Finite Element ◽  
Pressure Distribution ◽  
Finite Element Simulations ◽  
Process Conditions ◽  
Fiber Placement ◽  
Static Testing ◽  
Contact Width ◽  
Automated Fiber Placement

Application of automated fiber placement is limited by defects formed in the prepreg tows during the layup process. An extensive experimental study is performed to investigate the effect of compaction roller on the quality of the layup. Five different compaction rollers with different stiffness and architectures were manufactured and employed to dispense prepreg tows at various process conditions. Layup quality was examined and different defects including tow buckling and blister were identified. In addition to automated fiber placement trials, static testing and finite element simulations were performed to probe the pressure distribution and contact width of each roller. This data was used to support and understand the results of the automated fiber placement trials. Results indicate the solid elastomer rollers that are compliant enough to produce the same level of contact width under similar levels of compaction forces are superior to the perforated rollers in terms of achievable layup quality.

An improved path discretization method for automated fiber placement

2020 ◽  
Vol 39 (13-14) ◽  
pp. 545-559
Author(s):  
Ruming He ◽  
Weiwei Qu ◽  
Yinglin Ke
Keyword(s):  
The Finite Element Method ◽  
Fiber Placement ◽  
Curved Structures ◽  
Discrete Algorithms ◽  
Discretization Algorithm ◽  
Normal Error ◽  
Pressure Experiment ◽  
Automated Fiber Placement ◽  
Laying Head ◽  
The Relationship

In the automated fiber placement process, the continuous placement paths need to be discretized into a finite number of path points because the laying head cannot continuously trace the predetermined curved path. However, the discretization of the placement path, which is a spatial curve, will inevitably introduce error. In this paper, an improved path discretization algorithm is proposed for the fiber placement of complex double-curved structures. Firstly, the discrete error was decomposed into normal direction and binormal direction, and they are correlated with the laying process and their influences on the laying quality are discussed, respectively. Secondly, the relationship between the binormal error and the overlap of the tow is analyzed with differential geometry, and the influence of the normal error on laying force is discussed by the pressure experiment and the finite element method. Finally, the improved path discretization algorithm has been verified on double-curved surface and compared with the traditional path discrete algorithms. The results showed that the number of discrete path points decreases by 45.8% on average compared with the chordal deviation discretization algorithm and by 63.1% compared with the equal-arc discretization algorithm.

Automated Fiber Placement of Composite Wind Tunnel Blades: Process Planning and Manufacturing

2019 ◽  
Author(s):  
Ramy Harik ◽  
Joshua Halbritter ◽  
Dawn Jegley ◽  
Ray Grenoble ◽  
Brian Mason
Keyword(s):  
Wind Tunnel ◽  
Process Planning ◽  
Fiber Placement ◽  
Automated Fiber Placement

scholarly journals Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1951
Author(s):  
Yi Di Boon ◽  
Sunil Chandrakant Joshi ◽  
Somen Kumar Bhudolia
Keyword(s):  
Processing Parameters ◽  
Filament Winding ◽  
Reference Points ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Fiber Placement ◽  
Automated Fiber Placement

Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

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