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

Cheng, Jinxiang; Zhao, Ding; Liu, Kai; Wang, Yangwei; Chen, Huaiyuan

doi:10.1177/0731684418798151

Cited by 18 publications

(15 citation statements)

References 38 publications

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“…Cheng et al. 22 studied the contact characteristic and the morphological change of the prepreg under the roller. But there are few reports on how to improve the roller adaptability to molds and increase the pressure uniformity through optimizing the structure of the roller.…”

Section: Introductionmentioning

confidence: 99%

“…21 For this type, Lichtinger et al 16 analyzed the deformation behavior of the roller on the chamfered sandwich mold numerically and experimentally. Cheng et al 22 studied the contact characteristic and the morphological change of the prepreg under the roller. But there are few reports on how to improve the roller adaptability to molds and increase the pressure uniformity through optimizing the structure of the roller.…”

Section: Introductionmentioning

confidence: 99%

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Pressure distribution for automated fiber placement and design optimization of compaction rollers

Jiang

2019

Journal of Reinforced Plastics and Composites

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During automated fiber placement, insufficient compaction pressure leads to low bond strength between layers and may cause defects like bridging. The compaction roller contacts the prepreg and affects the pressure distribution directly. In this article, a model for analyzing the adaptability of rollers to molds is established. Then, compaction pressure distribution on prepreg tows is analyzed by finite element simulation and verified by pressure sensitive film experiment. Based on the simulation results, a calculation method of pressure uniformity is proposed. Moreover, the design parameters of the roller are optimized with an aim of improving pressure uniformity. The results show that the pressure uniformity can be improved significantly by design optimization of the roller, which indicated that higher bond quality between layers is achieved.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Pressure distribution for automated fiber placement and design optimization of compaction rollers

Jiang

2019

Journal of Reinforced Plastics and Composites

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“…The trajectory of the tape on the liner was a helical path which defined the gap between the adjacent layers accordingly. To avoid possible overlaps at the tape edges, the helix pitch should be a bit larger than the as-received prepreg width since the tape width expands during the heating and consolidation phases [20,40]. The tape laying head moved in lateral (x-) direction with a distance being equal to the tape width (w) for each full rotation.…”

Section: Methodsmentioning

confidence: 99%

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

Hosseini

Schäkel

Baran

et al. 2020

Int J Adv Manuf Technol

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The non-uniform temperature and crystallinity distributions present in carbon fiber–reinforced PA12 composite pipes, produced via laser-assisted tape winding (LATW), are investigated in this paper. The width of the laser source is usually larger than the substrate width which causes multiple heating and cooling of some regions of the (neighboring) substrate and hence temperature and crystallinity gradients during the adjacent hoop winding. A kinematic-optical-thermal (KOT) model coupled with a non-isothermal crystallinity model is developed to capture the transient temperature and crystallinity distributions for growing substrate thickness and width. The predicted temperature trends are validated with thermocouple and thermal camera measurements. The substrate temperature varies in the width direction up to 52%. This will lead to extra polymer remelting and possible degradation. The maximum variation of the crystallinity degree across the width is found to be 270% which shows agreement with the trend of the measured crystallinity degree. It is found that a more realistic description of the melting behavior of the matrix is needed to obtain a more accurate prediction of the crystallinity distribution.

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“…In the same way, Stokes-Griffin and Compston [2] showed the effect of consolidation force and laser power on bonding strength, for which the roller deformation is taken into account. In addition, some recent works showed clearly the impact of the compression and the roller deformation on the consolidation between the incoming tape and substrate [14,15].…”

Section: Introductionmentioning

confidence: 98%

Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters

Baho

Ausias

Grohens

et al. 2020

Int J Adv Manuf Technol

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Laser-assisted automated fiber placement (AFP) is highly suitable for an efficient production of thermoplastic-matrix composite parts, especially for aeronautic/aerospace applications. Heat input by laser heating provides many advantages such as better temperature controls and uniform heating projections. However, this laser beam distribution can be affected by the AFP head system, mainly at the roller level. In this paper, a new optico-thermal model is established to evaluate the laser energy quantity absorbed by a poly(ether ether ketone) reinforced with carbon fibers (APC-2). During the simulation process, the illuminated radiative material properties are characterized and evaluated in terms of the roller deformation, the tilt of the robot head, and the reflection phenomenon between the substrate and the incoming tape. After computing the radiative source term using a ray-tracing method, these data are used to predict the temperature distribution on both heated surfaces of the composite during the process. The results show that both the roller deformation and the tilt of head make it possible to focus the laser beam on a small area, which considerably affects the quality of the finished part. These findings demonstrate that this optico-thermal model can be used to predict numerically the insufficient heating area and thermoplastic composites heating law.

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

Cited by 18 publications

References 38 publications

Pressure distribution for automated fiber placement and design optimization of compaction rollers

Pressure distribution for automated fiber placement and design optimization of compaction rollers

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

Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters

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