Title: Integrated Design and Manufacturing Analysis for Automated Fiber Placement Structures

Authors: August Noevere, Craig Collier, and Ramy Harik

DOI: 10.33599/nasampe/s.19.1500

Abstract: Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed “Central Optimizer” tool will be used to tie the modules together and drive the design for manufacturing process.

References: [1] Noevere, A., Collier, C., “Integrated AFP Manufacturing and Stress Analysis/Design Process.” 2018 American Society of Composites Technical Conference, Seattle, WA, 2018 [2] Sloan, J., “The first composite fuselage section for the first composite commercial jet.” Composites World, July 2018. Accessed Jan 2019. https://www.compositesworld.com/articles/the-first-composite-fuselage-section-for-the-first-composite-commercial jet [3] MTorres, “MTorres provides technology change to Airbus 350 wings lamination.” MTorres.es, Dec 2015. Accessed Jan 2019. http://www.mtorres.es/en/communication/news/mtorres-afps-airbus-350-wings# [4] Gardiner, G., “Tooling up for larger launch vehicles.” Composites World, Feb 2013. Accessed Jan 2019. https://www.compositesworld.com/articles/tooling-up-for-larger-launch-vehicles [5]DeVlieg, R., Jeffries, K., Vogeli, P., “High-Speed Fiber Placement on Large Complex Structures.” SAE International, 2007. 2007-01-3843 [6] Noevere, A., Collier, C., “Mapping Manufacturing Data for Stress Analysis of Automated Fiber Placement Structures.” 2018 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Kissimmee, FL, 2018, https://doi.org/10.2514/6.2018-0228 [7] Vericut Composite Programming, Software Package, Ver. 8.1, CGTech, Irvine, CA, 2019. [8] HyperSizer, Software Package, Ver. 7.3, Collier Research Corporation, Newport News, VA, 2019. [9] Noevere, A., Collier, C., Harik, R., Halbritter, J., “Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures.” 2019 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, San Diego, CA, 201, https://doi.org/10.2514/6.2019-0520 [10] Abaqus, Software Package, Ver. 2018, Dassault Systemes, Velizy-Villacoublay, France, 2018 [11] COMPRO, Software Package, Convergent, Vancouver, BC, Canada, 2018 [12] Forghani, A., Hickmott, C., Hutten, V., Bedayat, H., Wohl, C., Grimsley, B., Coxon, B., Poursartip, A., Experimental Calibration of a Numerical Model of Prepreg Tack for Predicting AFP Process Related Defects, SAMPE 2018 Technical Conference and Exhibition, Long Beach, CA, 2018 [13] Bedayat, H., Forghani, A., Hickmott, C., Palmieri, F., Grimsley, B., Coxon, B., Fernlund, G., Poursartip, A., Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and their Effect on Porosity, SAMPE 2018 Technical Conference and Exhibition, Long Beach, CA, 2018

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1500

Pages: 17

Price: FREE