scholarly journals Influence of Automated Fiber Placement Parameters on Thermoplastic Composite Blanks Used on Stamp Forming Process

2021 ◽  
Author(s):  
Camille Vernejoux ◽  
Xavier Fischer ◽  
Simon Deseur ◽  
Emmanuel Duc
Keyword(s):  
Production Costs ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Advanced Manufacturing ◽  
Forming Process ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Stamp Forming ◽  
Manufacturing Time

In recent years, advanced manufacturing processes have been developed to increase the speed of production in order to reduce production costs. At the scale of thermoplastic composites, the translation is the combination of advanced manufacturing processes. The focus in this study is more specifically on the coupling of automated lay-up (AFP) and stamp forming processes. To date, a consolidation process, such as press-consolidation of thermoplastic composites, obtained blanks. Several trials have begun using an automated fiber placement consolidation to reduce manufacturing time and use unidirectional material. However, the combination of AFP and stamp forming is useful if it optimizes this process without the blank’s full consolidation, which by resulting reduces the manufacturing time. This study estimates blank characteristics through thermal history imposed by a more rapid manufacturing process. A set of blanks with varying process parameters is produced to investigate the influence at the microscopic scale. The interface behaviour is observed with optical microscope and image processing. A statistical study applied to the process is carried out in order to relate the material observations to the input parameters. The results of this study are used for the study of the next process of the combination: the stamp forming.

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.

scholarly journals Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters

2020 ◽  
Vol 110 (7-8) ◽  
pp. 2105-2117
Author(s):  
Omar Baho ◽  
Gilles Ausias ◽  
Yves Grohens ◽  
Julien Férec
Keyword(s):  
Laser Beam ◽  
Laser Heating ◽  
Thermal Model ◽  
Laser Energy ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Efficient Production ◽  
Fiber Placement ◽  
Aerospace Applications ◽  
Automated Fiber Placement

Abstract Laser-assisted automated fiber placement (AFP) is highly suitable for an efficient production of thermoplastic-matrix composite parts, especially for aeronautic/aerospace applications. Heat input by laser heating provides many advantages such as better temperature controls and uniform heating projections. However, this laser beam distribution can be affected by the AFP head system, mainly at the roller level. In this paper, a new optico-thermal model is established to evaluate the laser energy quantity absorbed by a poly(ether ether ketone) reinforced with carbon fibers (APC-2). During the simulation process, the illuminated radiative material properties are characterized and evaluated in terms of the roller deformation, the tilt of the robot head, and the reflection phenomenon between the substrate and the incoming tape. After computing the radiative source term using a ray-tracing method, these data are used to predict the temperature distribution on both heated surfaces of the composite during the process. The results show that both the roller deformation and the tilt of head make it possible to focus the laser beam on a small area, which considerably affects the quality of the finished part. These findings demonstrate that this optico-thermal model can be used to predict numerically the insufficient heating area and thermoplastic composites heating law.

EFFECT OF THERMAL INPUT ON THE TEMPERATURE DISTRIBUTION OF THERMOPLASTIC COMPOSITES MADE BY AUTOMATED FIBER PLACEMENT (AFP)

2021 ◽  
Author(s):  
MEHRSHAD MOGHADAMAZAD ◽  
SUONG V. HOA
Keyword(s):  
Thermoplastic Composite ◽  
Heat Transfer Analysis ◽  
Thermoplastic Composites ◽  
Experimental Measurements ◽  
Convection Coefficient ◽  
Fiber Placement ◽  
Hot Gas ◽  
Temperature Distributions ◽  
Automated Fiber Placement ◽  
Theoretical Results

The heat transfer analysis of thermoplastic composite manufactured using automated fiber placement with a hot gas torch can be done using numerical methods such as finite difference method. The accuracy of the theoretical results depends upon the accuracy of the thermal inputs. The hot gas/air temperature and convection coefficient distributions between the hot gas and the surface of the substrate (thermal inputs) have the significant influence on the accuracy of the resulting theoretical temperature distributions in the deposited laminate. A model predicting theoretical results which agree with experimental measurements is presented

Thermal stresses in rings of thermoplastic composites made by automated fiber placement process

2011 ◽  
Vol 18 (1-2) ◽  
pp. 35-49 ◽  
Author(s):  
Qi Zhao ◽  
Suong V. Hoa ◽  
Zhan Jun Gao
Keyword(s):  
Heat Transfer ◽  
Thermal History ◽  
Thermal Stresses ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Thermally Induced ◽  
Fiber Placement ◽  
Ansys Simulation ◽  
Hot Air ◽  
Automated Fiber Placement

AbstractThe automated fiber placement (AFP) of thermoplastic composites has a complex thermal history, which seriously leads to residual stresses in the products. An ANSYS simulation model is proposed to predict thermal history and induced thermal stresses in thermoplastic composite rings. It attempts to simulate closely the AFP process by adding materials incrementally. The processing speed was modeled by incrementally moving the hot air heater along the outer surface of the composite cylinder. The analysis is time-dependent, including two steps of transient heat transfer and induced thermal stress analyses. The heat transfer characteristics and the accumulated thermal effect during processing are investigated. Thermally induced stresses are examined.

EFFECT OF PROCESSING PARAMETERS ON THE WIDTHS AND THICKNESSES OF THERMOPLASTIC COMPOSITES MADE BY AUTOMATED FIBER PLACEMENT

2021 ◽  
Author(s):  
DUC MINH HOANG ◽  
SUONG VAN HOA
Keyword(s):  
Applied Pressure ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Engineering Structures ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
The Individual ◽  
Placement Machine ◽  
Curved Panels

The advent of Automated Fiber Placement (AFP) machine has expanded the capacities to manufacture engineering structures using thermoplastic composites. Structures of cylindrical shapes, flat and curved panels can be easily made using this technique. As more applications and more studies have been made on this technique for thermoplastic composites, many issues have come up. One issue of importance is the variation of the width and thickness of the tow as it is deposited. As the melted thermoplastic composite tow is being pressed under the compression force of the roller, the material flows. This changes the width and the thickness of the tow. The values of the width and thickness depend on many parameters such as the properties of the substrate, the temperature of the material, and the applied pressure. This variation in width and thickness of the individual tow being deposited has an influence on the development of laps and gaps between the deposited tows. This paper presents some of the results on an investigation on the above topic. Widths and thicknesses of carbon/PEEK tows processed using an Automated Fiber Placement machine with a hot gas torch were examined. Preliminary results show that there is significant variation in the width and thickness of the tows upon deposition.

scholarly journals Automated fabrication of hybrid thermoplastic prepreg material to be processed by In-Situ Consolidation Automated Fiber Placement process

2018 ◽  
Vol 188 ◽  
pp. 01024
Author(s):  
Vincenzo Iannone ◽  
Marco Barile ◽  
Leonardo Lecce
Keyword(s):  
Carbon Fiber ◽  
Hot Forming ◽  
Framework Programme ◽  
Thermal Cycles ◽  
Forming Process ◽  
High Performing ◽  
Fiber Placement ◽  
Research And Innovation ◽  
Automated Fiber Placement

This work deals with the fabrication of an innovative hybrid thermoplastic prepreg by continuous hot forming process. The material, suitable also for Automated Fiber Placement process, is produced through a consolidation of commercial PEEK-Carbon Fiber prepreg sandwiched between two amorphous PEI films. Consolidation is performed by a purpose-designed automated prototype equipment operating on defined pressure and thermal cycles. Then preliminary tests on first trials produced were carried out. These activities have been developed in the frame of the NHYTE project, a Research and Innovation Action funded by the European Union's H2020 framework programme, under Grant Agreement No 723309 NOVOTECH acting as Coordinator presents this paper on behalf of all Partners of the project. The proof of NHYTE project concept is the manufacturing of a fastener free and high performing fuselage portion demonstrator.

Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods

2017 ◽  
Vol 31 (12) ◽  
pp. 1676-1725 ◽  
Author(s):  
Khaled Yassin ◽  
Mehdi Hojjati
Keyword(s):  
Heat Transfer ◽  
Quality Parameters ◽  
Thermoplastic Composites ◽  
Transfer Model ◽  
Scanning Calorimetry ◽  
Intimate Contact ◽  
Fiber Placement ◽  
Hot Gas ◽  
Lap Shear ◽  
Automated Fiber Placement

Fiber-reinforced composite materials are replacing metallic components due to their higher specific strength and stiffness. Automation and thermoplastics emerged to overcome the time and labor intensive manual techniques and the long curing cycles associated with processing thermoset-based composites. Thermoplastics are processed through fusion bonding which involves applying heat and pressure at the interface. Together with automated techniques (such as automated fiber placement, and automated tape laying), a fast, clean, out-of-autoclave, and automated process can be obtained. A detailed review of thermoplastic composites processing through automated methods is presented. It sheds the light on the materials used and the different heat sources incorporated with the pros and cons of each, with concentration mainly on hot gas torch, laser, and ultrasonic heating. A thorough illustration of the several mechanisms involved in a tow/tape placement process is tackled such as heat transfer, intimate contact development, molecular interdiffusion, void consolidation and growth, thermal degradation, crystallization, and so on. Few gaps and recommendations are included related to materials, laser heat source, heat transfer model, and the use of silicone rubber rollers. A review of optimization studies for tape placement processes is summarized including the main controllable variables and product quality parameters (or responses), with some of the major findings for laser and hot gas torch systems being presented. Both mechanical and physical characterizations are also reviewed including several testing techniques such as short beam shear, double cantilever beam, lap shear, wedge peel, differential scanning calorimetry, and so on. Challenges, however, still exist, such as achieving the autoclave-level mechanical properties and complying with the porosity levels required by the aerospace industry. More work is still necessary to overcome these challenges as well as increase the throughput of the process before it can be totally commercialized.

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