Automated manufacture of optimised shape-adaptive composite hydrofoils with curvilinear fibre paths for improved bend-twist performance

Maung, Phyo Thu; Prusty, B. Gangadhara; Donough, Matthew J.; Oromiehie, Ebrahim; Phillips, Andrew W.; John, Nigel A. St

doi:10.1016/j.marstruc.2022.103327

Cited by 14 publications

(7 citation statements)

References 29 publications

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“…Since the strain was tared, the strain in the sensor would increase linearly despite the fact that there may be localised signal drop due to a higher strain gradient at higher loading between adjacent sensing points [59]. The peak strain recorded by the sensors is, in fact, representative of the maximum strain under similar quasi-static loading runs and strains monitored under comparable static loading [39]. This also signifies the capability of the optical sensor to perform without any optical loss in comparison to the initial condition.…”

Section: Strain Monitoringmentioning

confidence: 98%

“…As the hydrofoil is designed to be loaded in flexure the carbon fibre/epoxy layers are expected to dominate the structural performance. The dimensions of the hydrofoil and its AFP based manufacturing process are presented elsewhere [39].…”

Section: Geometry and Manufacturing Of The Hydrofoilmentioning

confidence: 99%

“…Prior quasi-static testing in conjunction with finite element analysis on the hydrofoil had shown that a 14 kN peak load would produce the required 2000 µε strain near the root [39]. The loading details for the specimen are given in table 1.…”

Section: Loading Schemementioning

confidence: 99%

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Smart monitoring of a full-scale composite hydrofoil manufactured using automated fibre placement under high cycle fatigue

Shamsuddoha¹,

Prusty²,

Maung³

et al. 2021

Smart Mater. Struct.

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Fibre reinforced composites materials offer a pathway to produce passive shape adaptive smart marine propellers, which have improved performance characteristics over traditional metallic alloys. Automated fibre placement (AFP) technology can provide a leap forward in cyber-physical automated manufacturing, which is essential for the implementation and operation of smart factories in the marine propeller industry towards Industry 4.0 readiness. In this paper, a comprehensive structural health monitoring routine was performed on an AFP full-scale composite hydrofoil to gain confidence in its dynamic and structural performances through a number of active and passive sensors. The hydrofoil was subjected to constant amplitude flexural fatigue loading in a purpose-built test rig for 105 cycles. The hydrofoil was embedded with distributed optical fibre sensors, traditional electrical strain gauges and linear variable displacement transducers. Both microelectromechanical system and piezoelectric accelerometers were used to conduct experimental modal analyses to observe changes in the modal response of the hydrofoil at regular intervals throughout the fatigue program. The hydrofoils modal response, as well as the stiffness measured using both displacements and strains, remained unchanged over the fatigue loading regime demonstrating the structural integrity of the hydrofoil. The optical fibre sensors endured the fatigue test cycles showing their robustness under fatigue loads. Furthermore, the sensing systems demonstrated the potential of being utilised as a useful maintenance tool combining their adaptability with automated manufacturing during manufacturing through integration within the hydrofoil, a structural test framework for performance measurement, data acquisition and analytics for visualisation, and the prospect of decision making for maintenance requirement during any onset in structural performance.

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Section: Strain Monitoringmentioning

confidence: 98%

Section: Geometry and Manufacturing Of The Hydrofoilmentioning

confidence: 99%

See 1 more Smart Citation

Smart monitoring of a full-scale composite hydrofoil manufactured using automated fibre placement under high cycle fatigue

Shamsuddoha¹,

Prusty²,

Maung³

et al. 2021

Smart Mater. Struct.

View full text Add to dashboard Cite

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“…Further, the in-service internal strains were monitored by embedding DFOSs in a wide variety of composite structures varying from composite panels, pressure vessels, wind turbine blades, and composite sandwich panels in different research studies. [24][25][26][27][28][29][30][31][32][33] Besides the DFOSs, FBG-based OFSs were also embedded into different composite structures for monitoring the curing process and for SHM applications. [34][35][36][37][38][39][40][41] However, in the above-mentioned studies, the aforementioned fabrication and material aspects associated with the OFs embedment into VRI composite structures were not addressed.…”

Section: Introductionmentioning

confidence: 99%

Mechanical and optical performance evaluations of embedded polyimide and PEEK coated distributed optical sensors in glass fibre reinforced composites with vinyl ester resin systems

Nagulapally

Shamsuddoha

Herath³

et al. 2023

Journal of Composite Materials

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Embedded optical fibre sensors (OFSs) offer the potential to monitor the internal strains at various stages during the manufacturing and service life of fibre-reinforced polymer (FRP) composite structures. Various aspects associated with the embedment of OFSs, such as integration, material compatibility, and sensing performance of the embedded sensor needs to be investigated to develop reliable OFSs based internal sensing platform for composite structures. In this study, Polyimide (PI) and Polyether ether ketone (PEEK) coated optical fibres (OF) were embedded into glass fibre-reinforced polymer (GFRP) composites to evaluate four important aspects associated with the embedment of OFs, which include; i). Structural integrity of the OFs against chemical reactions from vinyl ester resin and its additives through immersion testing, ii). Methods of integrating the OFs into layered glass fibres for the vacuum resin infusion manufacturing process, iii). Sensing performance of the embedded OFs during manufacturing and structural testing (tensile and compressive), and iv). Internal structural integrity of the embedded OFs and the host composite structure using X-Ray micro-computerised tomography technique (μ-CT). The results from the immersion testing and manufacturing process monitoring showed that both PEEK and PI coated OFs can resist the chemical and mechanical stresses caused by resin polymerisation during curing process. The subsequent mechanical testing showed a similar sensing performance by the PI and PEEK coated OFs. Under tensile loads, the OFs monitored the tensile strain distribution up to 7,000 με and compressive strain distribution up to −1,200 με under flexural loading without compromising their optical performance. Finally, the μ-CT scanning results had shown a minimal structural deterioration of the embedded OFs and host composite structure. The outcomes from this detailed experimental investigation on the embedment of OFS in GFRP structures provided useful information towards the integration and performance of optical sensors in composite structures.

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“…The advanced manufacturing methods used for FRP production, such as automated fibre placement, enable the manufacture of complex geometries with minimal waste, thus moving away from conventional subtractive manufacturing. Structures with tailored mechanical properties can also be formed [1,2] to resist the applied load and customisable mechanical behaviour in operation. This production process, however, requires the machining of a bespoke mould, incurring substantial capital costs and restricting design flexibility.…”

Section: Introductionmentioning

confidence: 99%

Design and Manufacture of Mould Free Fibre Reinforced Laminates with Compound Curvature

Jenkins,

Donough,

Prusty

2023

Preprint

Self Cite

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Composite manufacturing demands mould tooling to produce dimensionally accurate parts, adding substantial capital costs to their production. Recent developments in advanced manufacturing of fibre-reinforced polymer composite elements have seen the implementation of mould-free technologies that can produce complex shaped parts off a flat tool. This paper presents eccentric fibre prestress as a novel mould-free method for producing curvatures within carbon fibre and glass fibre laminates. Tailoring the flexural rigidity along the primary orientation of the laminate is shown to result in a complex, compound curvature profile with high accuracy. An analytical model based on Euler-Bernoulli beam theory is proposed and demonstrated to correlate closely with the experiential laminates. An inverse design approach based on a Genetic Algorithm is demonstrated to design a reasonable laminate configuration to achieve the top surface of a NACA 4412 aerofoil section using the proposed eccentric fibre prestress.

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Automated manufacture of optimised shape-adaptive composite hydrofoils with curvilinear fibre paths for improved bend-twist performance

Cited by 14 publications

References 29 publications

Smart monitoring of a full-scale composite hydrofoil manufactured using automated fibre placement under high cycle fatigue

Smart monitoring of a full-scale composite hydrofoil manufactured using automated fibre placement under high cycle fatigue

Mechanical and optical performance evaluations of embedded polyimide and PEEK coated distributed optical sensors in glass fibre reinforced composites with vinyl ester resin systems

Design and Manufacture of Mould Free Fibre Reinforced Laminates with Compound Curvature

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