Title: Minimizing through Thickness Defect Stack-Up for Automated Fiber Placement of Composite Laminates via Fiber Path Optimization

Authors: Joshua Halbritter, Noah Swingle, Roudy Wehbe, Ramy Harik

DOI: 10.33599/nasampe/s.22.0689

Abstract: UofSC’s neXt Composite research team developed the Computer Aided Process Planning (CAPP) software to support process planning for automated fiber placement (AFP) manufacturing. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of the laminate. The ply optimization functions on the measurement and scoring of geometry-based defects such as gaps, overlaps, angle deviation, and steering. This paper presents laminate level process planning optimization that focuses on mitigating defect stacking through the thickness of the laminate. This is achieved by generating laminate scenarios from the best ply scenarios and comparing the defects of each ply through the thickness to identify regions where defects are stacking on top of each other. The frequency and severity of stacked defects are then described using a novel scoring system, allowing process planners to craft fiber paths that mitigate the number of geometry-based defects and the compounding effect they have throughout a laminate. The paper also presents a case study of the laminate optimization technique performed with a doubly curved tool surface to demonstrate the novel scoring system and the resulting minimization of through thickness defect interactions.

References: [1] R. Harik, C. Saidy, S. J. Williams, Z. Gurdal and B. Grimsley, ""Automated fiber placement defect identity cards: cause, anticipation, existence, significance, and progression,"" Long, 2017. [2] J. Halbritter, ""Automation of Process Planning for Automated Fiber Placement,"" 2020. [3] X. Li, S. R. Hallett and M. R. Wisnom, ""Modelling the effect of gaps and overlaps in automated fibre placement (AFP)-manufactured laminates,"" Science and Engineering of Composite Materials, vol. 22, p. 115–129, 3 2015. [4] M. Lan, D. Cartié, P. Davies and C. Baley, ""Microstructure and tensile properties of carbon–epoxy laminates produced by automated fibre placement: Influence of a caul plate on the effects of gap and overlap embedded defects,"" Composites Part A: Applied Science and Manufacturing, vol. 78, p. 124–134, 11 2015. [5] K. Croft, L. Lessard, D. Pasini, M. Hojjati, J. Chen and A. Yousefpour, ""Experimental study of the effect of automated fiber placement induced defects on performance of composite laminates,"" Composites Part A: Applied Science and Manufacturing, vol. 42, p. 484–491, 5 2011. [6] K. Fayazbakhsh, M. A. Nik, D. Pasini and L. Lessard, ""Defect layer method to capture effect of gaps and overlaps in variable stiffness laminates made by Automated Fiber Placement,"" Composite Structures, vol. 97, p. 245–251, 3 2013. [7] A. W. Blom, C. S. Lopes, P. J. Kromwijk, Z. Gurdal and P. P. Camanho, ""A Theoretical Model to Study the Influence of Tow-drop Areas on the Stiffness and Strength of Variable-stiffness Laminates,"" Journal of Composite Materials, vol. 43, p. 403–425, 1 2009. [8] A. Sawicki and P. Minguett, ""The effect of intraply overlaps and gaps upon the compression strength of composite laminates,"" in 39th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference and Exhibit, 1998. [9] A. T. Noevere, C. Collier, R. F. Harik and J. Halbritter, ""Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures,"" AIAA Scitech 2019 Forum, 2019. [10] O. Falcó, J. A. Mayugo, C. S. Lopes, N. Gascons and J. Costa, ""Variable-stiffness composite panels: Defect tolerance under in-plane tensile loading,"" Composites Part A: Applied Science and Manufacturing, vol. 63, p. 21–31, 8 2014. [11] J. P.-H. Belnoue, T. Mesogitis, O. J. Nixon-Pearson, J. Kratz, D. S. Ivanov, I. K. Partridge, K. D. Potter and S. R. Hallett, ""Understanding and predicting defect formation in automated fibre placement pre-preg laminates,"" Composites Part A: Applied Science and Manufacturing, vol. 102, p. 196–206, 11 2017. [12] CGTech, VERICUT Composite Programming, 2021. [13] G. Rousseau, R. Wehbe, J. Halbritter and R. Harik, ""Automated Fiber Placement Path Planning: A state-of-the-art review,"" Computer-Aided Design and Applications, vol. 16, p. 172–203, 8 2018.

Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000689

Pages: 14

Price: $28.00