Hybrid Prepreg Tapes for Composite Manufacturing: A Case Study

The aim of this research was the preparation and characterization of hybrid prepreg tapes from glass multifilament roving (circular cross-section). The fiber, roving, and tape strength distribution was characterized by exploratory data analysis tools (especially quantile-quantile plot) and modeled by the three parameters’ Weibull distribution. For estimation of Weibull model parameters, the noniterative technique based on the so-called Weibull moments was used. It was shown that the prepared hybrid prepreg tapes prepared by controlled mechanical spreading technology developed by the authors improved mechanical tensile properties and can be used for the preparation of composites of complicated forms by robotic winding.

NUMERICAL ANALYSIS OF INFUSION STRATEGIES IN VACUUM ASSISTED RESIN TRANSFER MOLDING (VARTM) PROCESS

The Liquid composite Molding (LCM) process, such as Vacuum Assisted Resin Transfer Molding (VARTM), offers a fast and high-quality production of composites laminates. In the VARTM process, the simulation tool is found beneficial to predict and solve composite manufacturing issues. The part quality is dependent on the resin mold filling stage in the VARTM process. The infiltration of resin into a porous fibrous medium is taken place during the resin mold filling stage. The permeability has a crucial role during the resin mold filling stage. In this study, simulation of resin infusion through multiple injection gates is discussed. The various infusion schemes are simulated to identify defect-free composite manufacturing. The simulation approach is applied to five different stacking sequences of reinforcements. In this transient simulation study, permeability and resin viscosity is essential inputs for the resin flow. The simulation approach found that a gating scheme plays a vital role in mold filling time and defect-free composite fabrication. It is found that the line gating system can be useful for fast mold filling over the point gating system.

A cooperative mobile robot and manipulator system (Co-MRMS) for transport and lay-up of fibre plies in modern composite material manufacture

Composite materials are widely used in industry due to their light weight and specific performance. Currently, composite manufacturing mainly relies on manual labour and individual skills, especially in transport and lay-up processes, which are time consuming and prone to errors. As part of a preliminary investigation into the feasibility of deploying autonomous robotics for composite manufacturing, this paper presents a case study that investigates a cooperative mobile robot and manipulator system (Co-MRMS) for material transport and composite lay-up, which mainly comprises a mobile robot, a fixed-base manipulator and a machine vision sub-system. In the proposed system, marker-based and Fourier transform-based machine vision approaches are used to achieve high accuracy capability in localisation and fibre orientation detection respectively. Moreover, a particle-based approach is adopted to model material deformation during manipulation within robotic simulations. As a case study, a vacuum suction-based end-effector model is developed to deal with sagging effects and to quickly evaluate different gripper designs, comprising of an array of multiple suction cups. Comprehensive simulations and physical experiments, conducted with a 6-DOF serial manipulator and a two-wheeled differential drive mobile robot, demonstrate the efficient interaction and high performance of the Co-MRMS for autonomous material transportation, material localisation, fibre orientation detection and grasping of deformable material. Additionally, the experimental results verify that the presented machine vision approach achieves high accuracy in localisation (the root mean square error is 4.04 mm) and fibre orientation detection (the root mean square error is 1.84∘) and enables dealing with uncertainties such as the shape and size of fibre plies.

Study on Structural Design and Analysis of Composite Boat Hull Manufactured by Resin Infusion Simulation

In this paper, structural design and analysis of a composite boat hull was performed. A resin transfer molding manufacturing method was adopted for manufacturing the composite boat hull. The RTM process is an advanced composite manufacturing method that allows a much higher quality product than the hand lay-up process, and less manufacturing cost compared to the autoclave method. Therefore, the RTM manufacturing method was adopted. The mechanical properties of the various aramid fibers and polyester resin were investigated. Based on this, structural design of boat hull was performed using aramid fiber or polyester. After structural design, the optimized resin infusion analysis for RTM manufacturing method was performed. Through the resin infusion analysis, it is confirmed that the designed location of resin injection and outlet is acceptable for manufacturing.