Title: Integration of Structural Analysis and Manufacturing Process Planning for Global Optimization with Automated Fiber Placement

Authors: August Noevere, Von Jamora & Ramy Harik

DOI: 10.33599/nasampe/s.24.0141

Abstract: Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.

References: [1]HyperX, Software Package, Ver. 2023.3.9, Collier Research Corporation, Newport News, VA, 2023. [2]Vericut Composite Programming, Software Package, Ver. 9.4, CGTech, Irvine, CA, 2023. [3]A. Brasington, J. Halbritter, M. Godbold, M. Kirkpatrick, C. Sacco, R. Harik, “Mapping of multimodality data for manufacturing analyses in automated fiber placement”, Composites Part B: Engineering, 263, 2023. https://doi.org/10.1016/j.compositesb.2023.110881 [4]A. Brasington, J. Halbritter, R. Wehbe, R. Harik, “Bayesian optimization for process planning selections in automated fiber placement”, Journal of Composite Materials, 56, 2022 [5]N. Swingle, A. Brasington, J. Halbritter, R. Harik, “Implementation of Combinatorial Optimization Techniques for Automated Fiber Placement through Thickness Defect Stack-Up Minimization”, SAMPE 2023 Conference & Exhibition, Seattle, WA, 2023 [6]A. Brasington, J. Halbritter, A. Noevere, R. Harik, “Integration of Design Data into Automated Fiber Placement Process Planning Metrics”, SAMPE 2023 Conference & Exhibition, Seattle, WA, 2023 [7]J. Halbritter, N. Swingle, R. Wehbe, R. Harik, “Minimizing Through-Thickness Defects Stack-up for Automated Fiber Placement of Composite Laminates via Fiber Path Optimization”, SAMPE 2022 Conference & Exhibition, Charlotte, NC, 2022 [8]J. Halbritter, R. Harik, C. Saidy, A. Noevere, B. Grimsley, (May 2019). Automation of AFP Process Planning Functions: Importance and Ranking. SAMPE Conference & Exhibition. Charlotte, North Carolina, US. [9]A. Noevere and C. Collier, 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 [10]A. Noevere and C. Collier, 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, 2019 [11]A. Noevere and C. Collier, Design for Manufacturing Tool for Automated Fiber Placement Structures – Verification and Validation, 2020 AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Orlando, FL, 2020 [12]R. Younsi, I. El-Batanony, J.-B. Tritsch, H. Naji, and B. Landjerit, “Dynamic study of a wind turbine blade with horizontal axis,” Eur. J. Mech. - ASolids, vol. 20, no. 2, pp. 241–252, Mar. 2001, doi: 10.1016/S0997-7538(00)01127-X. [13]G. Fernandez, H. Usabiaga, and D. Vandepitte, “An efficient procedure for the calculation of the stress distribution in a wind turbine blade under aerodynamic loads,” J. Wind Eng. Ind. Aerodyn., vol. 172, pp. 42–54, Jan. 2018, doi: 10.1016/j.jweia.2017.11.003. [14]Abaqus/CAE, Ver. 63-1, Dassault Systèmes, Vélizy-Villacoublay, France, 2023. [15]CATIA, Software Package, Ver. 5, Dassault Systems, Velizey, France, 2022. [16]A. Noevere, Effects of Defects Analysis and Sizing Framework for Efficient Design of Composite Structures, SAMPE 2022 Technical Conference and Exhibition, Seattle, WA, 2022

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000141

Pages: 14

Price: $28.00