Composite Laminate Surface Analysis for Steep Ramp Angle Prediction
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Solution Overview
Problem
Current methods for designing and manufacturing composite structures lack robust tools for predicting the exact placement of material, leading to steep ramp angles in composite laminates that are not fully defined by engineering part definitions, resulting in increased inspection time and potential laminate quality issues.
Innovation Solution
A computer analysis method that simulates the placement of composite structures using wide tape material, predicts the contours of the bag-side surface, and adjusts ply boundaries to minimize steep angles, thereby improving the surface smoothness and reducing inspection time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wide tape material is cut in situ by robotic placement device, then manufacturing flexibility and adaptability are improved, but the resulting laminate has steep ramp angles and poor surface smoothness
Solution Approach 1:
The method performs preliminary analysis and prediction of the as-programmed surface contours before manufacturing. By calculating the bag-side surface geometry and identifying steep ramp angles in advance, the system can adjust ply definitions and tow placement parameters beforehand to prevent poor surface quality, rather than detecting and correcting it after manufacturing.
Solution Approach 2:
The system implements a feedback loop where the predicted as-programmed surface is analyzed, steep ramp angles are identified, and the ply definitions are iteratively adjusted to improve surface smoothness. This closed-loop approach allows the manufacturing parameters to be optimized based on predicted outcomes.
2Productivity
If multiple tows are placed in parallel courses, then productivity and manufacturing efficiency are improved, but cut locations in close proximity create steep ramp angles requiring increased inspection time
Solution Approach 1:
The method performs preliminary identification of problematic cut locations and steep ramp angles before manufacturing by analyzing the as-programmed surface contours. This allows for preventive adjustment of ply definitions and tow placement patterns to avoid creating conditions that would require extensive inspection.
Solution Approach 2:
The system uses feedback from the surface analysis to iteratively refine the placement plan, adjusting ply boundaries and tow patterns to minimize steep ramp angles and reduce the number of problematic cut locations that would require additional inspection.
Data Source
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AI summary
A method (100) for computer analysis of a quality of an as-programmed surface of a composite laminate (22). A first data set representing an as-programmed top surface is generated based on as-programmed ply definitions and a tool surface definition (110). Thereafter, a second data set representing coordinates of points (42) of a first mesh on the as-programmed top surface is generated (112), which points form a first mesh (50). Then a third data set representing coordinates of points of a second mesh on a defined tool surface is generated (114). A respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh is then calculated (116). Each angle is compared to a threshold of acceptable angle (118). In response to an acceptable number of angles exceeding a threshold of acceptable angle, a tow placement machine may be programmed to fabricate a composite structure using the as-programmed ply definitions (136).