Composite Laminate Surface Analysis for Steep Ramp Angle Control
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Solution Overview
Problem
Current methods for designing and manufacturing composite parts lack robust tools for predicting the exact placement of material, leading to steep ramp angles in composite laminates that deviate from the engineering part definition, causing inspection challenges and potential structural issues.
Innovation Solution
A computer-based method for constructing composite parts using wide tape material, which includes an analysis technique to predict the contours of the bag-side surface before manufacture, and a construction method to improve laminate surface quality in steep ramp regions by reducing actualized angles to match the nominal angles defined in the engineering part definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tows are cut perpendicular to the fiber direction during automated placement, then the material can be precisely positioned and restarted, but the course boundary becomes non-smooth with triangular overlaps or gaps
Solution Approach 1:
The patent applies preliminary action by calculating and adjusting the tow cut locations and angles before the actual manufacturing process. The system predicts the as-programmed surface geometry and determines optimal cut parameters in advance to prevent steep ramp angles, rather than correcting issues after material placement.
Solution Approach 2:
The patent changes parameters by adjusting the tow cut angle and cut location based on the predicted surface geometry. Instead of always cutting perpendicular to the fiber direction, the system varies the cut angle to compensate for surface curvature and maintain smooth transitions, directly addressing the contradiction between precise positioning and boundary smoothness.
2Adaptability or versatility
If many tows are cut in close proximity during manufacturing, then the material placement flexibility is increased, but the resulting laminate has significantly steeper ramp angles than designed
Solution Approach 1:
The patent implements feedback by using the predicted as-programmed surface geometry to inform and adjust the tow placement and cutting parameters. The system continuously monitors the predicted surface contours and modifies cut locations and angles to maintain ramp angle accuracy, even when multiple tows are cut in close proximity.
Solution Approach 2:
The system performs preliminary calculation of the as-programmed surface and identifies potential steep ramp regions before manufacturing. This allows the system to pre-adjust cut parameters in areas where multiple tows will be placed close together, preventing ramp angle deviations before they occur.
3Ease of manufacture
If the exact position of tow cuts/restarts is determined by the coverage parameter, then the automated placement process is simplified, but the surface quality deviates from the engineering part definition
Solution Approach 1:
The patent replaces the simple coverage-parameter-based mechanical placement system with a computer-based predictive system. Instead of relying solely on geometric coverage calculations, the system uses computational models to predict the as-programmed surface and adjusts placement parameters accordingly, maintaining both automation and surface quality conformity.
4Productivity
If steep ramp regions are present in the composite laminate, then the manufacturing process is faster, but the surface quality and structural performance are compromised
Solution Approach 1:
The system performs preliminary prediction of the as-programmed surface to identify regions that would develop steep ramps during manufacturing. By detecting these regions before production, the system can adjust tow placement parameters in advance to maintain structural performance while minimizing impact on manufacturing speed.
Solution Approach 2:
The patent changes manufacturing parameters dynamically based on the predicted surface geometry. In regions prone to steep ramps, the system adjusts tow cut angles and positions to maintain surface quality and structural integrity, while in other regions it maintains faster placement rates, optimizing both productivity and reliability.
Data Source
AI summary
A method for computer analysis of a quality of an as-programmed surface of a composite laminate. A first data set representing an as-programmed top surface is generated based on as-programmed ply definitions and a tool surface definition. Thereafter, a second data set representing coordinates of points of a first mesh on the as-programmed top surface is generated, which points form a first mesh. Then a third data set representing coordinates of points of a second mesh on a defined tool surface is generated. A respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh is then calculated. Each angle is compared to a threshold of acceptable angle. 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.