Modeling and optimization of interlaminar bond strength for composite tape winding process

Abstract

The prepreg tape winding product of thermoset composite has been widely used in aerospace industry due to the favorable performance. The manufacturing process is the key to ensure the quality of product. This study is focused on the theoretical analysis of prepreg tape winding process. The mathematical model of thermal and consolidation process is established firstly. The influence mechanism of the major process parameters including heating temperature, consolidation force and winding velocity on consolidation quality is subsequently studied based on the simulation results. And the tape winding experiments and interlaminar shear strength tests are conducted to validate the predictive capability of the theoretical model. Moreover, the coupling role between the process parameters is explained based on the predicted model. In order to control the quality of winding product, the optimization of winding process is proposed, and the three-dimension process window of parameter settings is obtained.

Non-uniform crystallinity and temperature distribution during adjacent laser-assisted tape winding process of carbon/PA12 pipes

“…In situ consolidation, which is the main mechanism to form the final product, takes place at the nip point where the melted incoming tape and substrate bond due to pressure applied by a compaction roller. The consolidation process includes several highly temperaturedependent steps such as the development of intimate contact followed by the healing of the polymeric matrix, which was studied for the automated fiber placement (AFP) and laserassisted tape placement (LATP) processes in [13][14][15][16][17][18]. The inter-molecular diffusion or healing phenomenon describes the entanglement of polymer chains from one surface to the opposite one.…”

“…The absorbed heat at the illuminated surfaces is mainly dissipated in the thickness direction due to the heat sink behavior of the roller and liner; therefore, the melting temperature can be easily achieved in the sufficient depth of the substrate and tape for a proper consolidation. There have been several studies to evaluate the in situ consolidation development during LATP of carbon-reinforced thermoplastics [14,18,[20][21][22][23] and LATW of glass fiber/phenolic resin thermoset [16]. Also, the mechanical performance of the composite pipes was studied for various loading conditions [24][25][26].…”

Modeling and impact analysis on contact characteristic of the compaction roller for composite automated placement

“…The contact of the compaction roller has an effect on the prepreg morphology which is a vital phenomenon under the compaction roller. The study on the deformation of the prepreg contributes to studying the degree of intimate contact, 37,38 establishing the relationship between thickness and volume fraction, 26 decreasing the gap between fibers, 39 and so on. The deformation of the prepreg is related to the resin flow under the compaction roller.…”

Optimization of the laser-assisted tape winding process using an inverse kinematic-optical-thermal model

“…The process temperature, speed, compaction pressure [1][2][3][4][5], fiber path planning [6][7][8][9], and processinduced defects [10][11][12] are the important factors for developing a proper bonding quality at the interface between the tape and substrate to manufacture products with high mechanical performance. In addition, optimal ranges of the tape winding and placement parameters such as tape tension and roller force are necessary to reduce the void content [13,14] and residual stress [15,16] and to increase the tensile strength [13,15], interlaminar shear strength [17,18], peel strength [19,20], and production rate [16,18,19] The nip point temperature serves as an indicator for the process temperature and might vary during the LATW process, possibly resulting in a substantial variation in the consolidation quality.…”