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Experimental and Numerical Study on Defects and Repair of Automated Fiber Placement Features


Title: Experimental and Numerical Study on Defects and Repair of Automated Fiber Placement Features

Authors: Waruna Seneviratne, John Tomblin, Mohamed Shafie

DOI: 10.33599/nasampe/s.21.0626

Abstract: In the fabrication of complex aerospace structures, Automated Fiber Placement (AFP) has been considered to be one of the most advanced manufacturing methods. The primary feature of AFP fabrication method lies in the tow-by-tow/course-by-course placement of composite material using a robotic fiber placement head. While in the fabrication process, very fine tolerances are set to manage gaps and spacing in between fiber tows and courses; machine and operator errors along with part geometry limitations introduce AFP gap/overlap features within the construction. By understanding the effects due to these gaps and features, a better judgement of the process induced defect and the structural integrity of the part can be predetermined. In cases were gaps or missing tows are present within a composite layup, the local feature region becomes a resin rich area during the curing phase. This leads to intrinsic stress concentration due to the resin properties and the local fiber discontinuity. In this current study, such gap features are studied and a missing-tow repair-configuration during the manufacturing process has been evaluated in its effectiveness in dispersing the stress concentration. The repair configuration will be of a case where the gap is only detected after a subsequent ply is placed on top of the missing-tow. The main focus was to establish methods for developing knockdowns and design allowable which can be incorporated in the presence of such features. The knockdown effects were compared with pristine configurations of un-notched and open-hole test specimens under planar loading. Strength knockdown predications were also obtained using high fidelity finite element models to serve as a tool for comparison with test data. B-Spline analysis method (BSAM) developed under the Air Force Research Laboratories (AFRL) was used to predict failure strengths as well as to identify matrix crack/delamination propagation regions.

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Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000626

Pages: 15

Price: FREE

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