Infrared Heating Technology for Automated Fiber Placement

Prepreg stickiness is the adhesion between prepregs or between a prepreg and a mold in lay-up process.It is critical for automated fiber placement,because the stickiness should be small for smooth transport,as well as large enough on the laying surface for a good placement performance.To ensure prepreg stickiness always being in the optimum laying window,placement temperature should be changed according to the laying speed.In our work,the relationship between laying speed and emissive power of heating lamp was studied.The heat transfer process between heating lamp and laying surface was analyzed and the control equation of dynamic temperature was derived.Finally,the infrared heating system was built and its effectiveness was verified based on placement experiment.

Pressure Angle Effect of Concave Cylinder Surface on Motion Characteristics of Fiber Placement Machine

There are amounts of issues to be resolved in the process of designing the fiber placement trajectory of the cylindrical component,such as the interference between the machine and the component and the over-travel of the axis of rotation on the fiber placement head.When the pressure on the cylinder surface inclines in a certain direction or at an angle within the normal plane,the motion characteristics of the rotation axis will be different.This paper analyzes the pressure angle effect of the concave cylinder surface on the motion features of a fiber placement machine.The placement area is enlarged by tilting pressure with the same lifting stroke,which is significant in preventing interference and selecting post-processing algorithm.

Global Tool Path Fairing Algorithm for Automated Fiber Placement

A global energy fairing method,applied to automated fiber placement(AFP)tool path,was proposed.The main purpose was to improve the adaptability of AFP path towards part with sharp curvature variation as well as product quality.The relation between path geometric property and manufacturing property was discussed and a series of experiments were carried out.Based on cubic B-Spline global fairing method,the AFP tool path was faired which decreased the tool path curvature and curvature changing rate.Compared with initial ones,the path faired by the proposed method was relatively flat and smooth,which contributed to layup efficiency and reducing bulking defects.The method was demonstrated potentials in application for AFP manufacturing,especially for aeronautic and aerospace industry practice.

Temperature field characteristics of CF/PEEK thermoplastic composites formed by automated fiber placement using hot gas torch with slit structure nozzle

In-situ consolidation forming of high-performance thermoplastic composites by Automated Fiber Placement(AFP)is of significant interest in aerospace.During the laying process,the heating temperature has a great influence on the quality of the formed components.A threedimensional heat transfer finite element model of Carbon Fiber(CF)/Polyether Ether Ketone(PEEK)heated by Slit Structure Nozzle Hot Gas Torch(SSNHGT)assisted AFP is proposed.The influence of gas flow rate,heat transfer distance,and laying speed on heating temperature is analysed.The results show that the overall temperature increases and then decreases as the gas flow rate increases.With the increase in heat transfer distance and laying speed,the overall temperature decreases.Meanwhile,the gas flow rate has the greatest influence on the temperature of CF/PEEK being heated,followed by the laying speed and finally the heat transfer distance.Furthermore,the model can also be extended to other fiber-reinforced polymer composites formed by hot gas torch assisted AFP,which can guide the optimization of process parameters for subsequent heating temperature control.

Thermal management for thermoset automated fiber placement based on infrared heater structure arrangement

Layup temperature is a vital factor that affects the production quality of automated fiber placement for thermoset composites.For high quality production,this paper proposes a new prediction model of layup temperature by considering the structure of infrared heater of automatic fiber placement equipment.The model was first verified by comparing with the temperature results of layup experiments.Then a prediction on the effects of heater structure arrangement on layup temperature was conducted in the model.The research shows that the length of infrared tube and the radian of reflective-film have significant influences,rather than other parameters.According to this investigation,a heater structure-based heating strategy was presented in the paper to efficiently achieve constant temperature control in variable speed layup process.

Effect of variable-angle trajectory structure on mechanical performance of CF/PEEK laminates made by robotic fiber placement

In comparison to the traditional fixed-angle trajectory,the variable-angle trajectory has a greater design space.However,it is a challenge to determine which common design curve structure is the most effective for improving mechanical performance.This work explores the effects of various design curves such as fixed-angle curve,linear curve,arc curve,sine curve,Bezier curve,and cubic polynomial curve trajectories on mechanical performance of laminates,including vibration modal performance and buckling performance.Genetic algorithm and improved NSGA-II algorithm are then used to optimize various curve structures.The results are confirmed utilizing thermoplastic Carbon Fiber(CF)/Polyether-Ether-Ketone(PEEK)laminates made by robotic fiber placement experiments.The relationship model between different mechanical performance and curve design variables is established.The optimization of variable-angle structure with mechanical properties as input variables is achieved.Meanwhile,a full-process angle-variable laying software platform from trajectory planning(CAD),trajectory optimization to manufacturing(CAM)is developed for facilitating the fiber placement application.

Effect of gap and overlap on mode Ⅱ interlaminar fracture toughness of automated fiber placement prepreg laminates

Automated Fiber Placement(AFP)technology facilitates the manufacturing process of composite structures with complex geometry owing to its high efficiency and accuracy.However.the unavoidable imperfections induced by the automated layup method bring challenges to the stability of the final mechanical properties of composites.The influence of AFP-induced gaps and overlaps on the modeⅡinterlaminar fracture process of oven-cured laminates is experimentally investigated and explicitly revealed.End-Notched Flexure(ENF)tests were performed to measure the interlaminar fracture toughness of unidirectional laminates under three different defect configurations,namely"Gap""Overlap"and"Gap&Overlap".A marginal decline(about-1.2%in non-precracked tests,-5.1%in precracked tests)and an obvious increase(about 15.2%in nonprecracked tests,5.2%in precracked tests)in fracture toughness were observed for the"Gap"group and the"Overlap"group,respectively.Fractographic studies which involve the metallographic observation and Scanning Electron Microscopy(SEM)observation revealed that the increases in fracture area and crack length helped improve the fracture toughness of the Overlap"group.However,the resin-rich area with high porosity induced by gaps was detrimental to the delamination resistance.To capture the interlaminar stress distribution local to imperfections,a three-dimensional numerical model was established.Gap defects facilitate the local delamination process,and the overlap defect postpones the damage onset and the propagation.

Deviation-Rectifying Control of Carbon Fiber Prepreg Slitting and Winding Machine

With the growing needs of prepreg tapes for the automated fiber placement(AFP),the deviation-rectifying of prepreg in slitting process was investigated on a self-developed 16-tow prepreg slitting and winding machine.The process of slitting and rewinding of prepreg tape was introduced,and the reason of prepreg tape deviation in slitting process was analyzed.In order to ensure the quality of the narrow prepreg slits,the application of the fuzzy PID algorithm in a closed-loop control system was discussed.A fuzzy PID algorithm was designed by combining fuzzy rules and PID controller.By applying it to precise deviation-rectifying control strategy,the automatic control of rectification could be achieved with accuracy of 0.1 mm,which satisfies the requirement of the prepreg tape both in slitting quality and layup quality for AFP.

变刚度复合材料层合板研究进展

变刚度复合材料层合板由纤维曲线铺放而成,可以实现刚度分布的变化设计,与传统固定铺层角的复合材料层合板相比,变刚度复合材料层合板在减少重量和成本的同时,也提高了结构性能。随着铺放设备的发展,目前已经能够利用自动铺放技术实现纤维的曲线铺放。同时,为提高复合材料构件的结构性能和满足不同的工程实际需求,铺层设计方法也从单一角度的直线铺层逐渐向变角度曲线铺层发展。本文首先介绍了变刚度复合材料层合板设计制造方法与有限元建模,接着在刚度分布、屈曲特性、失效行为等方面阐述了变刚度复合材料层合板力学性能的研究进展,然后结合南京航空航天大学复合材料工程自动化技术研究中心在变刚度复合材料层合板振动特性方面的研究,对变刚度复合材料层合板振动特性进行了分析和概括,最后对变刚度复合材料层合板未来的研究趋势进行了论述与展望。

高速动车组横梁应变场光纤测量与反演研究

针对高速动车组车底底架横梁的应变场反演问题,基于模态叠加法和传感器优化配置理论,提出一种根据部分测点的实测单向应变反演结构空间应变场的方法。以结构的应变模态为输入,以模态坐标独立性为目标,基于信息熵理论建立了传感器优化配置的数学模型,再根据模态坐标和振型采用正则化方法反演结构应变场。仿真计算结果表明,无噪声干扰下,反演的精度较高,最大均方误差为9.87×10~(-12),并且正则化方法可以有效抑制噪声对结果的影响。搭建了基于光纤光栅传感系统的测试试验台,基于实测应变数据和模态结果反演应变场,结果表明,反演后的应变幅值相对误差带为1.21%~10.79%,反演数据和实测数据的均方误差带为0.80~3.69。该方法能够准确识别结构的模态坐标,为获取高速列车关键结构的应变场分布提供参考。

基于定制纤维铺放工艺的电加热织物制备及其半球成型性能

为开发既具有电热性能又满足对三维表面具有一定适应性的电加热织物,采用定制纤维铺放(TFP)工艺设计制备直线形、正弦波形、锯齿形和尖角形4种镍铬合金丝排布方式的电加热织物,研究电加热织物的电热性能和半球成型性能。结果表明:10 V直流电压下通电30 s,4种电加热织物表面最高平衡温度分别达到159.5、92.8、66.7和31.5℃,温度分布均匀;反作用力与镍铬合金丝排布方式密切相关;半球成型最终状态下,直线形电加热织物成型反作用力最小,表面褶皱和细观缺陷最少,且最大面内剪切角为32.26°;与未引入镍铬合金丝玻璃纤维基底织物相近,即直线形电加热织物半球成型性优于正弦波形、锯齿形和尖角形电加热织物。

梁类零件转角区域自动铺丝分析

在航空航天领域,自动铺丝已经被广泛应用于制造形状复杂的复合材料构件,C型梁就是其中的典型。C型梁结构通常具有曲率很大的转角过渡区域,保证该区域内的±45°路径铺放质量和铺放效率是C型梁结构铺放过程中的难题。为解决这一问题,分别研究了减丝束方法和缠绕方法对梁类零件转角区域铺放质量的影响,并进一步对比分析了减丝束法和缠绕法两种铺放策略在铺放转角区域时的优劣。建立了实际铺放过程中两种铺放策略的选择原则。最终通过实际铺放试验证明减丝束法和缠绕法相结合能够更有效地保证C型梁转角区域的铺放质量和铺放效率。

冗余铺放机器人的自运动流形及逆解优化研究

针对用于复合材料铺放成型的八自由度冗余机器人系统的逆运动学问题,提出了一种求解其自运动流形及逆解优化的算法。首先,基于位姿分离思想定义了位置子流形和姿态子流形,采用几何求解法得到了基于自运动变量的参数化方程形式的位置子流形和姿态子流形;然后,根据机器人的关节约束和实际铺放工艺过程,对给定的铺放位姿进行了位置子流形和姿态子流形配对的仿真,并用流形中若干组逆解通过正向运动学得到了末端位姿矩阵(其结果均与给定位姿相符,从而验证了自运动流形求解过程的正确性);最后,在完成自运动流形求解的基础上,从机械臂运动的平滑性和关节运动变化量两个方面出发,提出了一种基于自运动变量参数化方程的全局优化目标函数;以飞机尾椎模型为实验研究对象,对其中一条铺放路径进行了逆解全局优化仿真,得到了自运动变量和机器人各关节角在铺放路径上的优化曲线,将仿真结果与一种多目标优化算法进行了比较。研究结果表明:针对相同的铺放路径,采用上述优化算法后关节角变化总量降低了11.25%;该算法能够有效地求解八自由度冗余铺放机器人系统的自运动流形,基于全局优化目标函数,其能够在自运动流形中寻找出自运动变量和机器人各关节的最优解。该算法同样也适用于其他位姿解耦的冗余机器人系统逆解问题的求解。

干纤维自动铺放液体成型复合材料技术的研究进展

干纤维自动铺放液体成型复合材料技术是将自动铺放技术和液态成型技术结合,可同时实现先进复合材料的高韧化、自动化和低成本化,是复合材料扩大应用的重点发展方向之一。首先介绍了干纤维自动铺放液体成型复合材料技术的起源,然后分析了国外成熟的干纤维自动铺放材料的组成、性能和制备方法,归纳总结了国外干纤维自动铺放液体成型复合材料构件验证和应用情况,最后简单介绍了国内干纤维自动铺放液体成型复合材料技术现状,以期推动国内干纤维自动铺放液体成型技术的发展和应用。

基于网格模型的自动铺丝路径规划方法

针对复合材料自动铺丝工艺,研究基于网格模型的自动铺丝路径规划方法。梳理了自动铺丝路径规划的业务流程,对三角网格拓扑关系进行重建,节省数据存储空间;提出了基于给定点与方向的定向延伸算法,用于精确计算网格模型的线型路径点;对路径等距后的点集进行优化,避免了等距后的线型自交以及凸边现象,保证了线型的准确;对所规划路径的压辊可铺放性分析方法进行研究,并基于分析结果提出了路径优化策略。结合CATIA二次开发工具CAA在VS平台对自动铺丝路径规划模块进行开发,并通过实例验证了本文所研究方法的可行性与可靠性。

基于形态学的自动铺丝纤维铺放准确性检测

自动铺丝质量检查既耗时又不充分,缺陷对比度低。对此,根据铺丝过程中的热特性,搭建丝束铺放准确性检测平台,结合形态学算法对缺陷红外图像特征进行纤维铺放准确性检测。首先进行形状相同尺度不同的结构元素的顶帽变换,然后提取每一组尺度下多尺度亮暗区域和相邻组尺度间的多尺度亮暗细节来增强图像;其次使用了多方向多尺度的结构元素和系数自调节的形态学边缘检测算法来获得丝束边缘位置。实验结果表明,该方法在减少图像噪声和增强图像的对比度之上平衡了边缘检测精度与抗噪性能之间的协调问题,有效检测了纤维铺放准确性,最大铺放误差不超过4.53%。

工艺参数对CCF/PEEK预浸料单束铺放尺寸的影响

热塑性预浸料铺放过程中单丝束尺寸对整体构件铺放质量有重要影响,为提高连续碳纤维增强聚醚醚酮(CCF/PEEK)复合丝材铺放成型质量,研究了工艺参数对其在铺放过程中的单束宽度和厚度的影响规律,并根据实验结果建立拟合模型。首先设计正交实验,研究了铺放速度、铺放压力、加热温度等铺放工艺参数对CCF/PEEK预浸料宽度和厚度变化的影响规律,并由上述研究所得的影响宽度和厚度的最显著工艺参数,分别开展单因素实验研究。正交研究结果表明,各工艺参数对丝束宽度的影响显著程度依次为加热温度>铺放速度>铺放压力,对丝束厚度的影响显著程度依次为铺放压力>加热温度>铺放速度。单因素实验结果表明,在丝束不发生失效的工艺参数范围内,丝束宽度随加热温度的升高而增大,随铺放速度的提高而减小,随铺放压力的增大而增大。丝束厚度随铺放压力的增大而减小。采用多元线性回归方法对各工艺参数综合影响丝束宽度进行拟合,验证计算结果表明,建立的模型拟合效果较好。

变厚度帽型长桁加筋壁板自动铺丝工艺成形技术研究

针对帽型长桁加筋壁板的自动铺丝工艺成形技术进行了研究,并提出了帽型长桁加筋壁板各工序的关键工艺参数,通过研究自动铺丝设备的结构设计和控制系统设计,探究了帽型长桁加筋壁板的自动铺丝成形工艺,明确了自动铺丝间隙控制和工艺参数设计的基础,为帽型长桁加筋壁板的自动铺丝工艺成形技术的研究形成了一定的技术积累,具有较好的应用前景和经济效益。

中国复合材料自动铺放技术研究进展

首先扼要介绍了复合材料自动铺放(自动铺带和自动铺丝)成形技术的原理、特点和该技术在国外航空航天领域的应用概况。然后系统介绍了近年来中国国内复合材料自动铺带的装备技术、软件技术和材料工艺技术的研发历程,总结了其关键技术的突破和应用进展,并指出开发低成本高效铺带技术是未来的重要方向。同时介绍了国内自动铺丝技术基础研究(装备、软件和工艺方法)的进展,并且着重介绍了南京航空航天大学自动铺丝应用技术(工业样机与材料工艺技术)的研发和应用情况。最后通过分析,归纳了自动铺丝技术应用研究的瓶颈问题,并提出了研究建议。

纤维曲线铺放的变刚度复合材料损伤失效试验研究

根据纤维曲线铺放的变刚度复合材料层合板层内铺层角度的参考路径制备出铺层顺序分别为[±45/±〈45/60〉2/±〈15/30〉]s和[±45/±〈15/30〉/±〈45/60〉/±〈30/45〉]s的变刚度复合材料层合板,并对该变刚度复合材料层合板在拉伸和弯曲载荷作用下的损伤破坏过程进行了试验研究,获得了该复合材料层合板的损伤破坏演化过程。通过对纤维直线和纤维曲线铺放的复合材料层合板的拉伸和弯曲试验进行对比,结果表明:在拉伸载荷作用下纤维曲线铺放比纤维直线铺放的复合材料层合板的极限载荷和强度提高了49%和42%,在弯曲载荷作用下的极限载荷和强度提高了28%和32%;纤维直线铺放的复合材料层合板的断口破坏较为严重。纤维曲线铺放的变刚度复合材料层合板的结构性能得到了显著提高。