Efficient 3D temperature field prediction and visualization for AFP process analysis in composite structures

Abstract

Process modeling is an indispensable tool for establishing a foundation for process optimization and enhancing the quality of products. Analyzing the thermoforming process of polymer matrix composites presupposes the acquisition of accurate thermal histories. This paper introduces a numerical solution based on the finite difference (FD) model to predict the temperature field of angle‐ply composite structures during automated fiber placement (AFP) process along the machining trajectory. The proposed method incorporates three‐dimensional hybrid boundary conditions and considers temperature‐dependent material properties, significantly improving efficiency compared to the finite element (FE) model and overcoming challenges related to complex boundary conditions and anisotropic heat transfer in analytical solutions. Real‐time temperature measurement experiments were conducted to validate predictions, and further a specific temperature control strategy that meets process requirements was explored. In summary, the paper introduces a novel approach to address the temperature field in complex composite structure manufacturing processes.Highlights A novel 3D finite difference model predicts the temperature field in automated fiber placement. Improved prediction accuracy by managing complex boundary conditions. Effectively handled anisotropic heat transfer in complex composite structures. Superior efficiency over existing numerical methods. Developed a model‐based strategy for optimal temperature control within ±5°C.