No abstract

The optimisation and control of automated tape placement (ATP) requires fast analysis tools able to utilise process data for predictions and monitoring. In this study, a strategy for in-process estimation of nip point temperatures is proposed. The method is based on a combination of two one-dimensional analytical solutions of heat transfer in ATP using temperature data measured on the tool surface, combined with an inverse solution for the estimation of power delivered by the heating device on the composite surface. The performance of the method is examined against a validated finite element model. Approximations of nip point temperature show good correlation for different tool materials, with an average error of 15°C and a maximum of 50°C which is satisfactory for the processing of high-temperature thermoplastic materials. The analytical scheme offers real-time estimations of the nip point temperature with the potential to be used for process control of ATP.

A computationally efficient heat transfer simulation of flashlamp-assisted automated tape placement (ATP) is put forward in this work. The simulation combines distinct 1D finite element models representing the tow, the deposited material, and the resulting stack with appropriate transfer of temperature information to ensure field continuity. Direct comparison against a validated 2D model of ATP shows good agreement in the irradiation region, underneath and beyond the roller vicinity with errors up to 14°C. The combined solution of 1D models requires only 1-2% of the computational effort needed for an equivalent 2D analysis without compromising results resolution, whilst it is better suited for providing the full material temperature history throughout consecutive processing cycles. The accuracy and fast computation render this method appealing for studies which require an iterative execution of the model in a practical timeframe such as in optimisation schemes, inverse solutions, training of surrogate models and stochastic simulation.