Composite Layup Surface Geometry for AFP Flange Forming
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Solution Overview
Problem
The automated fibre placement (AFP) method struggles to lay-up fibrous structures on components with convex surfaces having small amplitude angles, such as those with flanges, due to the deposition head or roller's inability to access the bottom of these angles, leading to mechanical deformation and significant fibre stresses.
Innovation Solution
A method for determining a lay-up mould geometry with corrective curvatures and undulations to minimize fibre stresses, allowing the production of components with flanges by automated fibre placement, involving a first surface of revolution and a second surface with undulations and corrective curvatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lay-up is produced with larger amplitude angles to allow passage of the deposition head or roller, then the accessibility for automated fibre placement is improved, but the component geometry deviates from the desired small amplitude angles and requires subsequent mechanical deformation
Solution Approach 1:
The invention applies preliminary action by pre-calculating and incorporating corrective curvatures into the mould geometry before lay-up. The mould surface is designed with specific curvature corrections that compensate for the deformation that will occur during subsequent mechanical forming, allowing the fibres to be laid up in a stress-free state that will transform into the desired final geometry
Solution Approach 2:
The invention changes the geometric parameters of the mould surface by introducing corrective curvatures. The mould geometry is modified with specific curvature adjustments based on calculated deformation fields, transforming the mould from a simple replica of the final part geometry to a compensated surface that accounts for anticipated fibre stresses and deformations
2Manufacturing precision
If mechanical deformation is applied to obtain the desired angles, then the component geometry is corrected, but significant stresses are induced in the fibres especially close to the apex of the angle
Solution Approach 1:
The corrective curvatures are predetermined and built into the mould design before lay-up, performing the geometric correction in advance during the lay-up process itself rather than requiring post-lay-up deformation. This preliminary geometric compensation prevents fibre stress concentration that would occur during subsequent mechanical forming
Solution Approach 2:
The invention applies preliminary anti-action by designing the mould with curvatures that counteract the anticipated harmful effects of fibre deformation. The corrective curvatures create a pre-compensated fibre arrangement that resists the development of significant stresses during the forming process, particularly at critical locations like angle apices and fillets
3Strength
If a fillet is present between the flange and the body, then the component design is improved for stress distribution, but the fibre deformations are even more accentuated during lay-up and deformation
Solution Approach 1:
The invention applies local quality by implementing location-specific curvature corrections in the mould design. The corrective curvatures are not uniformly distributed but are specifically tailored to different regions of the mould surface, with enhanced corrections at critical locations such as fillet areas where fibre deformation is most problematic, while maintaining appropriate geometry in other regions
Data Source
AI summary
A method for determining a lay-up geometry for creating a component made of composite material, includes a body which is a volume of revolution of axis directed in an axial direction, the body extending around the axial direction in a circumferential direction, and a flange extending from one end of the body in a direction of extension, the method involving determining a first surface having the shape of the body that is to be produced and determining a second surface, situated in the prolongation of the first surface, the second surface having closed curves of undulation in the circumferential direction, wherein the second surface also has corrective curvatures in the direction of prolongation.