Title: Design Optimization and Analysis Validation of Complex Composite Parts Manufactured using Fiber Patch Placement

Authors: Waruna Seneviratne, Jerome Teoh, Swetha Thirumurugan

DOI: 10.33599/nasampe/s.25.0184

Abstract: Automated fiber placement (AFP) manufacturing techniques significantly increase production rates due to fewer interruptions and improved consistency, while reducing part count, lead-time and production cost with increased material yield compared to hand layup (HLU). However, the AFP process often results in scrap material due to leftover materials in the creel and faces challenges when laying up highly contoured small complex parts. When fibers are steered around complex counters, they tend to produce numerous defects and undesirable features such as puckers (wrinkles in inner radius of the tow) and overlaps. To overcome these challenges, a hybrid of additive and fiber placement technologies called fiber patch placement (FPP) is introduced for producing geometrically complex fiber composites and curvilinear reinforcements. This multi-robotic process enables a new degree of freedom in automated fiber deposition for complex shapes at a significantly higher rate than AFP and HLU. Upon completion of structural analysis and optimization, the design is transferred to a software package for optimizing reinforcement patch placement with the load path to meet design requirements and generating tool path and numerical computer (NC) codes for robot motions. Offline programming and simulation software provide an opportunity to access the manufacturing operation virtually, prior to executing the AFP process. With the use of high-performance robotics and advances in technology, FPP aims to aid in bridging the manufacturing requirements for production of geometrically complex fiber composite parts. This study discusses manufacturing and modeling methodologies to effectively engineer FPP parts with general practices for patch modeling, integrating FPP properties into finite element models and design analysis. Furthermore, this work aims to detail the manufacturing and testing performance of FPP composites though static and fatigue coupon level materials testing. Strength knockdowns due to fiber discontinuities were evaluated using flat panels with various patch overlap lengths for design optimization method development. Expanding on foundations and findings from the test and finite element modelling of FPP coupons [1], the validation effort was extended on to a part level cylindrical variable radius compression test article. In both cases, the test results closely matched with the analysis models, affirming the reliability of modeling tools in aiding complex FPP design

References: [1] D. L. Bourell, “Perspectives on additive manufacturing,” Annual Review of Materials Research, vol. 46, no. 1, pp. 1–18, Feb. 2016. (https://www.annualreviews.org/content/journals/10.1146/annurevmatsci-070115-031606) [2] H. Prüß and T. Vietor, “Design for Fiber-Reinforced additive manufacturing,” Journal of Mechanical Design, vol. 137, no. 11, Jul. 2015. (https://asmedigitalcollection.asme.org/mechanicaldesign/articleabstract/137/11/111409/474831) [3] J. L. Alqueres and J. C. Praca, "The Brazilian power system and the challenge of the Amazon transmission," in Proc. 1991 IEEE Power Engineering Society Transmission and Distribution Conf., pp. 315–320. [4] F.-W. Bach, A. Laarmann, and T. Wenz, Modern Surface Technology, Wiley-VCH Verlag GmbH & Co. KGaA, 2006. (https://doi.org/10.1002/3527608818) [5] G. Kim, E. Barocio, E. Tsutsui, P. Wang, S. Dubikovsky, R. Pipes, and R. Sterkenburg, “Enhancing surface characteristics of additively manufactured fiber-reinforced thermoplastic mold using thermoset coating with ceramic particles,” Surface & Coatings Technology, vol. 422, pp. 127536, Sep. 2021. (https://doi.org/10.1016/j.surfcoat.2021.127536) Composites Manufacturing and Simulation Center, Purdue University. Quiroa, Melgar, Pammi, Barocio, Kim. 1 [6] G. Kim, E. Barocio, and R. Sterkenburg, “Enhancing part demolding characteristics of additively manufactured fiber-reinforced polymer composite tools via surface coating,” Additive Manufacturing, vol. 46, Article 102072, 2021. (https://doi.org/10.1016/j.addma.2021.102072) [7] X. Zhang, J. Chen, J. Zhang, D. Wan, and Y. Zhou, “High-temperature mechanical and thermal properties of h-BN/30 vol%Y₂SiO₅ composite,” Ceramics International, vol. 41, no. 9, pp. 1089110896, May 2015. (https://doi.org/10.1016/j.ceramint.2015.05.030) [8] M. Lee, Y. Kim, and S. Park, “Impact of surface treatments on 3D-printed permanent resins,” Journal of Dentistry, vol. 48, no. 4, pp. 123–134, May (https://pmc.ncbi.nlm.nih.gov/articles/PMC11470446/) 2021. [9] J. Wang, L. Huang, and Z. Chen, “Influence of surface treatments on the chemical and mechanical properties of 3D-printed resins,” The Journal of Prosthetic Dentistry, vol. 129, no. 6, pp. 567–578, Jun. 2023. (https://www.thejpd.org/article/S0022-3913%2824%2900347-0/fulltext) [10] T. Green, R. Patel, and L. White, “Repair strength of 3D-printed denture base resins,” Dental Materials, vol. 42, no. 8, pp. 203–216, Jul. 2022. (https://pubmed.ncbi.nlm.nih.gov/39188160/) [11] H. Müller and K. Schmidt, “Effect of surface treatments on repair of 3D-printed permanent resins,” Materials Today Proceedings, vol. 16, no. 5, pp. 89–103, Nov. 2024. (https://assetseu.researchsquare.com/files/rs-1808447/v1/45c75b33-46d3-4cbc-bc36-29a5295504ad.pdf) [12] G. Sun, W. Du, C. Chen, and X. Zhao, “Hybrid additive manufacturing of ceramic/aluminumtitanium gradient composites via arc and laser cladding eutectic pools,” Virtual and Physical Prototyping, vol. 19, no. 1, 2024. (https://doi.org/10.1080/17452759.2024.2419950) [13] Chem-Trend L.P., Chemlease MPP 2180 Primer Technical Data Sheet, 2020.: (https://www.chemtrend.com) [14] K. D. Delaney, G. Bissacco, and D. Kennedy, “A structured review and classification of demolding issues and proven solutions,” International Polymer Processing, vol. 27, no. 1, pp. 77–90, 2012. (https://doi.org/10.3139/217.2514) [15] A. Sharma and V. K. Dwivedi, “Effect of milling parameters on surface roughness: An experimental investigation,” Materials Today: Proceedings, (https://doi.org/10.1016/j.matpr.2019.11.256) [16] 2020. Chem-Trend L.P., Chemlease 15 Sealer EZ Technical Data Sheet, 2020. (https://www.chemtrend.com) [17] ASTM International, Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor (Withdrawn 2022). (https://www.astm.org/d2583-13a.html) [18] ASTM International, Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser, 2019. (https://www.astm.org/d4060-19.html) Composites Manufacturing and Simulation Center, Purdue University. Quiroa, Melgar, Pammi, Barocio, Kim. 1 [19] TABER Industries, Taber Rotary Abraser (Abrader). (https://www.abrasiontesting.com/abrasiontesting-instruments/taber-rotary-platform-abraser-abrader/) [20] Â. R. Rodrigues, M. S. Correia, and A. J. Pontes, “Coefficient of friction in the demoulding forces of the injection moulding process—a review,” The International Journal of Advanced Manufacturing Technology, 2024. (https://doi.org/10.1007/s00170-024-14748-5) [21] ASTM International, Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting(Withdrawn 2023). (https://www.astm.org/d1894-14.htm) [22] Y. Guo, G. Liu, Y. Xiong, and Y. Tian, “Study of the demolding process—implications for thermal stress, adhesion, and friction control,” Journal of Micromechanics and Microengineering, vol. 17, no. 1, pp. 9–19, 2006. (https://doi.org/10.1088/0960-1317/17/1/002)

Conference: SAMPE 2025

Publication Date: 2025/05/19

SKU: TP25-0000000184

Pages: 15

Price: $30.00