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A Validation Study of a Physics-based Tack Model for an Automated Fiber Placement Process Simulation


Title: A Validation Study of a Physics-based Tack Model for an Automated Fiber Placement Process Simulation

Authors: Victoria Hutten, Alireza Forghani, Paulo Silva, Curtis Hickmott, Thammaia Sreekantamurthy, Christopher Wohl, Brian Grimsley, Brian Coxon, and Anoush Poursartip

DOI: 10.33599/nasampe/s.19.1512

Abstract: Automated Fiber Placement (AFP) offers a fast and more repeatable alternative for the fabrication of complex composite parts compared to traditional methods such as hand lay-up. Despite the performance advantages in the AFP process, geometry and process conditions may introduce defects that are not common in a hand lay-up process (e.g. wrinkles, puckers, fiber bridging, etc.). All of these critical defects are a form of fiber misalignment due to separation of the prepreg slit tape from the substrate. This research project, performed under NASA’s Advanced Composites Project, offers a physics-based framework for simulation of AFP processes with the aim of predicting defects as a function of tool geometry, tow course path, and process conditions including temperature, head speed, pressure, and tow tension. The physics-based framework includes a representation of the AFP head, the slit tape, and the substrate. A key component of the model is the tack that is formed between the substrate and the slit tape during deposition. A rate-dependent cohesive model is developed to simulate the complex tack response between the two surfaces. Previous papers and presentations by the authors focused on the tack model development and validation; however, this paper focuses on the simulation framework and sensitivity due to the simulation setup (e.g. element type, section definition, mass scaling, damping) and its affect on defect prediction.

References: [1] Ahn et al., 1992. Analysis and characterization of prepreg tack. Polymer Composites, 13(3), pp.197–206. [2] Crossley et al., 2013. Time-temperature equivalence in the tack and dynamic stiffness of polymer prepreg and its application to automated composites manufacturing. Composites Part A: Applied Science and Manufacturing, 52, pp.126–133. Available at: [3] Dubois, O., Le Cam, J.-B. & Béakou, A., 2010. Experimental analysis of prepreg tack. Experimental Mechanics, 50(5), pp.599–606. [4] Forghani et al. Simulating prepreg tack in AFP process. 32nd American Society of Composites Technical Conference. West Lafayette, IN United States, Oct 22-25, 2017. American Society of Composites. [5] Forghani et al. A physics-based modelling framework for simulation of prepreg tack in AFP process. SAMPE Technical Conference. Seattle, WA United States of America, May 22-25, 2017. Society for the Advancement of Material and Process Engineering. [6] Forghani et al. Experimental calibration of a numerical model of prepreg tack for predicting AFP process related defects. SAMPE Technical Conference. Long Beach, CA United States of America, May 21-24, 2018. Society for the Advancement of Material and Process Engineering. [7] Crossley et al. The experimental determination of prepreg tack and dynamic stiffness. Composites Part A 2012;43(3):423–34. [8] Endruweit et al. Characterisation of tack for uni-directional prepreg tape employing a continuous application-and-peel test method. Composites Part A 2018; (114):295-306.

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1512

Pages: 8

Price: FREE

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