Study of integral hat-stiffened composite structures manufactured by automated fiber placement and co-curing process

Zhao, Cong; Wang, Xianfeng; Liu, Xingyu; Cheng, Mengqi; Chu, Qian-Qian; Xiao, Jun

doi:10.1016/j.compstruct.2020.112427

Cited by 8 publications

(5 citation statements)

References 26 publications

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“…During the clamping, retransfering, and layup stages, the tow tension fluctuates dramatically due to changes in speed, mold curvature, etc. And according to the previous paragraph, such fluctuations could affect the placement quality [21]. However, the pattern of tension fluctuations is not yet clear.…”

Section: Introductionmentioning

confidence: 96%

“…The results showed that choosing the appropriate path parameters can decrease the risk of unreasonable path planning and enhance the effectiveness. Through tow feeding and laying tests, Xiao et al [21] investigated the tension during the laying process. The results of tows feeding trials showed that the tension greatly affected the tows' feeding reliability and precision.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of Precise Tension with Passive Dancers for Automated Fiber Placement

Li,

Che,

Zheng

et al. 2024

Actuators

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This paper modeled the tension fluctuation during automated fiber placement (AFP), which depicted the tension variations under different operating conditions. The stability and validity of the model were demonstrated using Bode plots and experiments, respectively. According to the model, the tension fluctuations of AFP at different stages were obtained. Additionally, the passive dancer parameters with the better system performance were determined using the evaluation methodology presented in this paper. Moreover, it was discovered that the damping coefficient affects the tension variation more significantly than the elasticity coefficient. Finally, the placement experiments showed that the determined passive dancer parameters improved the laying quality significantly.

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Section: Introductionmentioning

confidence: 96%

Section: Introductionmentioning

confidence: 99%

Modeling of Precise Tension with Passive Dancers for Automated Fiber Placement

Li,

Che,

Zheng

et al. 2024

Actuators

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“…Also reusing the material requires elaborate preparation [10,11]. Expandable cores made of rubber such as silicone are limited in their ability to be demolded from undercuts and are too soft to be used as a mandrel for fiber lay-up and debulking [12]. First, papers covering cores for the automated production of hollow composite profiles using removable mandrels were published in the late 1990s.…”

Section: Introductionmentioning

confidence: 99%

Variable Shape Tooling for Composite Manufacturing: A Systematic Review

Neumann

2024

J. Compos. Sci.

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The choice of material, manufacturing process, and molding tool significantly affects the quality, environmental impact, and cost efficiency of composite components. Producing one-piece hollow profiles with smooth inner surfaces and undercuts presents major challenges for conventional mold concepts. There is yet no thorough review of shape-variable mandrels in composite manufacturing to be found in the literature. This paper provides an overview of research on shape memory polymers and other shape-variable materials used in tooling applications for composite manufacturing. This work covers shape memory, heat shrink, and other deformable tooling concepts that enable the production of one-piece Type V pressure vessels, air intake ducts, or curved struts and tubes. A systematic literature review in combination with a state-of-the-art open-source active learning tool ASReview is conducted. Fifteen relevant studies were identified. Research on shape-variable tooling is mainly conducted by three research groups in the USA and the PRC. The tooling is mostly made of unreinforced thermosets, especially styrene-based ones. Thermoplastic resins are less common, and reinforcements limit the usable elongation in the temporary shape. The shape variability is either a shape memory and/or a softening process, which, in all studies, is activated by heating. Release agents are widely used to ease demolding. No ecological or economical assessment of the manufacturing methods was conducted in the reviewed studies. Three fields for further research that could be identified are as follows: (1) thorough ecological end economical assessment of shape-variable mandrels in comparison with conventional tooling; (2) thermoplastic shape memory polymer mandrels; and (3) further investigation of simulation capabilities for shape memory mandrels.

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“…Compared with the former five opensectional stiffeners, the hat stiffeners are in close section and exhibit higher torsional rigidity and strength-to-weight ratio. [3][4][5][6][7][8] In addition, the hat stiffeners have many other advantages, i.e., (1) the special geometrical configuration allows a greater spacing of the stiffeners due to their own width; (2) the enclosed space between the stiffener and the skin can effectively be utilized as a duct for the passage of cables; (3) the minimal fuel loss when used in wet bays; (4) compatible with most composite prepreg systems; (5) OML tooling approach easy to design and use; (6) the contour can be relatively easy to control. 9 In one word, the hat stiffeners have clear advantages over the open-sectional stiffeners, which makes them to be one of the most widely used structure concepts in the fuselages and wings of airplanes.…”

Section: Introductionmentioning

confidence: 99%

Effects of the fillers on the interface strength of the hat-stiffened composite panel

Liu,

Guan

2023

Polymers and Polymer Composites

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Hat-stiffened composite skins have been widely used in primary structures of aircraft components. The bonding strength at the stiffener-skin interface is critical to ensure the advanced load-bearing capacity of the stiffened skin, whereas, the deltoid regions are usually the weakest locations because of the geometrical singularity. Inserting fillers into the deltoid regions could alter the bonding strength. In this study, a series of four-point bending tests are conducted on the co-cured hat-stiffened composite skin specimens with and without fillers and with different pre-fabricated debonding defects, furthermore, finite element simulations are implemented to predict the failure process. The stiffness, initial failure load, failure mode and failure process are analyzed to obtain the influences of the fillers on the damage tolerance of the hat-stiffened composite panels, and the influential mechanisms were revealed by the combined analyses of the test and simulation results. It is found that the usage of fillers can increase the initial stiffness of the panel without prefabricated defects by about 10%, but provide limited influence on the initial failure load. The pre-fabricated debonding defect along longitudinal direction has little influence on the stiffness and failure load, but the influence of the defect along transverse direction are higher. The initial failure of all hat-stiffened composite panels with/without filler and with/without prefabricated defects under four-point bending onsets around the deltoid region. The usage of the fillers changed the load transfer and the stress status in the deltoid region of the hat-stiffened composite panels and as a consequence, the initial failure modes were changed and the failure load were increased by the fillers. This work provides a technical support for the damage tolerance design and strengthening method of hat-stiffened composite structures.

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Study of integral hat-stiffened composite structures manufactured by automated fiber placement and co-curing process

Cited by 8 publications

References 26 publications

Modeling of Precise Tension with Passive Dancers for Automated Fiber Placement

Modeling of Precise Tension with Passive Dancers for Automated Fiber Placement

Variable Shape Tooling for Composite Manufacturing: A Systematic Review

Effects of the fillers on the interface strength of the hat-stiffened composite panel

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