Level of automation (LOA) in aerospace composite manufacturing: Present status and future directions towards industry 4.0

Jayasekara, D. C.; Lai, Nai Yeen Gavin; Wong, Kok-Hoong; Pawar, Kulwant S.; Zhu, Yingdan

doi:10.1016/j.jmsy.2021.10.015

Cited by 29 publications

(4 citation statements)

References 43 publications

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“…Depending on the feeding of the UD tapes, unassembled from a reel or preassembled from a cassette, a distinction is made between single-stage and two-stage or dual systems, as a combination of both process options. This technology is currently mainly used to produce load-resistant lightweight structures with adapted fiber orientation in the aviation industry [29].…”

Section: Introductionmentioning

confidence: 99%

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

Hirsch,

Scholz,

Borowitza

et al. 2024

JMMP

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Fused granular fabrication (FGF) is a large format additive manufacturing (LFAM) technology and focuses on cost-effective granulate-based manufacturing by eliminating the need for semifinished filaments. This allows a faster production time and a broader range of usable materials for tailored composites. In this study, the mechanical and morphological properties of FGF test structures made of polyamid 6 reinforced with 40% of short carbon fibers were investigated. For this purpose, FGF test structures with three different parameter settings were produced. The FGF printed structures show generally significant anisotropic mechanical characteristics, caused by the layer-by-layer building process. To enhance the mechanical properties and reduce the anisotropic behavior of FGF structures, continuous unidirectional fiber-reinforced tapes (UD tapes), employing automated tape laying (ATL), were subsequently applied. Thus, a significant improvement in the flexural stiffness and strength of the manufactured FGF structures was observed by hybridization with 60% glass fiber-reinforced polyamide 6 UD tapes. Since the effectiveness of UD-tape reinforcement depends mainly on the quality of the bond between the UD tape and the FGF structure, the surface quality of the FGF structure, the interface morphology, and the tape-laying process parameters were investigated.

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Section: Introductionmentioning

confidence: 99%

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

Hirsch,

Scholz,

Borowitza

et al. 2024

JMMP

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“…With the development of the global market, composite materials have significantly penetrated the manufacturing strategies of many industries, such as automotive, rail transport, the space industry, aircraft construction, etc., with one of the main goals being the reduction of the overall weight and improvement of various characteristics of the products, which directly affect the life cycle of the final product [1], [2], [3], [4], [5], [6], [7].…”

Section: Introductionmentioning

confidence: 99%

A Case Study of Simulating Various Number of Gate Positions and Their Impact Through T-RTM Technology

Bankov

2024

ETR

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The study presented aims to investigate the influence from different gate positioning on the final product in T-RTM technology. The research is done using the specialized Moldex3D software. The studies conducted found that the symmetrical arrangement of injection ports and the approach to progressive injection with reduced pressure on the secondary gates result in significantly better deformation outcomes, with values close to 95% better compared to the deformation results in the approach with simultaneously open ports.

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“…2 AFP technology is currently being used to manufacture both flat (frames, stringers) and highly contoured (wing skins, fuselage barrels) structures. 3 The process consists of a gantry or robotic system with an attached fiber placement end effector. The attached fiber placement head allows rapid and repeatable deposition of strips of composite material which additively form the final structure.…”

Section: Introductionmentioning

confidence: 99%

Bayesian optimization for process planning selections in automated fiber placement

Brasington

Halbritter

Wehbe

et al. 2022

Journal of Composite Materials

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Since the arrival of Automated Fiber Placement (AFP) in the 1980s and 1990s, the manufacturing technique has been progressively improving in quality and reliability of the process and resulting structures. The state-of-the-art of AFP is allowing for the manufacture of structures with increasing geometrical complexity. To adequately manufacture such structures, a large effort in process planning is required to reduce defect occurrence to the best extent possible. Many optimization methodologies have been established for AFP in terms of the design and process parameters. However, limited work has been accomplished in terms of process planning optimization. The work presented in the latter will develop a Bayesian Optimization (BO) technique for the optimization of process planning with the use of the Computer Aided Process Planning (CAPP) software and its connection with Vericut Composite Programming (VCP). A case study is performed on a doubly curved tool surface and the optimal solution is compared with as-manufactured results for validation. A predictive tool is also developed to rank layup strategies based on defect importance. Results show a substantial improvement in defect occurrence and allow a process planner to immediately see the performance of various layup strategies and starting point combinations.

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Level of automation (LOA) in aerospace composite manufacturing: Present status and future directions towards industry 4.0

Cited by 29 publications

References 43 publications

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

A Case Study of Simulating Various Number of Gate Positions and Their Impact Through T-RTM Technology

Bayesian optimization for process planning selections in automated fiber placement

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