Multiscale Collaborative Optimization of Processing Parameters for Carbon Fiber/Epoxy Laminates Fabricated by High-Speed Automated Fiber Placement

Abstract

Processing optimization is an important means to inhibit manufacturing defects efficiently. However, processing optimization used by experiments or macroscopic theories in high-speed automated fiber placement (AFP) suffers from some restrictions, because multiscale effect of laying tows and their manufacturing defects could not be considered. In this paper, processing parameters, including compaction force, laying speed, and preheating temperature, are optimized by multiscale collaborative optimization in AFP process. Firstly, rational model between cracks and strain energy is revealed in order that the formative possibility of cracks could be assessed by using strain energy or its density. Following that, an antisequential hierarchical multiscale collaborative optimization method is presented to resolve multiscale effect of structure and mechanical properties for laying tows or cracks in high-speed automated fiber placement process. According to the above method and taking carbon fiber/epoxy tow as an example, multiscale mechanical properties of laying tow under different processing parameters are investigated through simulation, which includes recoverable strain energy (ALLSE) of macroscale, strain energy density (SED) of mesoscale, and interface absorbability and matrix fluidity of microscale. Finally, response surface method (RSM) is used to optimize the processing parameters. Two groups of processing parameters, which have higher desirability, are obtained to achieve the purpose of multiscale collaborative optimization.

Multi-Scale Low-Entropy Method for Optimizing the Processing Parameters during Automated Fiber Placement

“…Thus, a novel multi-scale energy transfer model that is applicable for orthotropic materials should be built. The energy transfer model is further studied based on Reference [ 34 ].…”

Multiphase Flow Coupling Behavior of Bubbles Based on Computational Fluid Dynamics during AFP Process: The Behavior Characteristics of Bubbles during AFP Process

“…Fiber Reinforced Plastics/composites (FRPs) have been widely used for many years in the aerospace, naval, automotive, and civil applications due to their several advantages over traditional materials (e.g., metals), such as high stiffness and strength to weight ratio, more excellent fatigue resistance, better long-term durability, lower thermal expansion and superior corrosion resistance [1][2][3][4]. Such advantages make FRPs an ideal candidate for a wide range of applications involving extreme operational conditions [5][6][7][8].…”

Defect Characteristics and Online Detection Techniques During Manufacturing of FRPs Using Automated Fiber Placement: A Review

“…Among them, automated fiber placement (AFP) appeared in the 1970s in the aerospace industry. It combines the advantages of filament winding and automated tape laying to overcome their limitations and exploit their benefits, and is one of the fastest-growing and most effective fully automated manufacturing technologies for composite materials in recent years [ 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 ]. AFP technology can be used not only for producing thermosetting or thermoplastic composites but also for dry fiber placement [ 13 , 14 , 15 ].…”