Fiber Path Planning for Composite Layup Curvature Reduction
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Solution Overview
Problem
Automated fiber placement manufacturing faces challenges in producing composite layups with complex shapes while maintaining specified fiber angle orientations, leading to defects like folds, puckers, and increased manufacturing time due to high in-plane curvature of fiber paths.
Innovation Solution
A system and method for planning fiber paths that determine a first unit vector field based on a specified rosette direction and surface approximation of a nonplanar contoured surface, then adjust to a second unit vector field with reduced in-plane curvature within specified angle deviation bounds, to optimize fiber placement head paths for AFP machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber paths are planned to follow the specified fiber orientation on complex nonplanar surfaces, then the fiber angle orientation is maintained, but the in-plane curvature increases causing tow cohesion issues, folds, and puckers
Solution Approach 1:
The patent modifies the fiber path parameters by adjusting the unit vector field to reduce in-plane curvature while maintaining fiber orientation within specified angle deviation bounds. This involves changing the mathematical representation of fiber paths from direct surface following to optimized paths that account for curvature constraints, thereby preventing tow cohesion issues while preserving essential fiber orientation.
Solution Approach 2:
The patent introduces dynamic adaptation in fiber path planning by using iterative optimization processes that adjust path parameters based on local curvature conditions. The system dynamically modifies the unit vector field to balance fiber orientation requirements with curvature constraints, allowing the fiber paths to adapt to local geometric conditions and prevent defects.
2Manufacturing precision
If fewer and smaller tows are used to maintain fiber orientation, then the fiber angle precision is improved, but the manufacturing time increases due to more courses required
Solution Approach 1:
The patent optimizes the relationship between tow size, number of courses, and fiber path curvature. By modifying the fiber path parameters to reduce in-plane curvature, the system enables the use of fewer and smaller tows without excessive manufacturing time penalty, as the optimized paths reduce the number of sharp turns and direction changes required.
Solution Approach 2:
The patent performs preliminary fiber path optimization before manufacturing by pre-calculating the optimized unit vector field that minimizes in-plane curvature. This advance planning allows for efficient tow placement with fewer courses, as the optimal paths are determined beforehand, avoiding the need for excessive maneuvering during actual manufacturing.
3Manufacturing precision
If the fiber placement head follows sharp turns to maintain fiber orientation, then the fiber angle specification is met, but the in-plane curvature causes folds and surface flaws
Solution Approach 1:
The patent changes the fiber path parameters by optimizing the unit vector field to reduce in-plane curvature. This modification allows the fiber placement head to follow smoother paths that meet fiber angle specifications within acceptable deviation bounds while avoiding sharp turns that cause folds and surface flaws.
Solution Approach 2:
The patent converts the harmful effect of high in-plane curvature into a beneficial optimization goal. By identifying in-plane curvature as the source of folds and surface flaws, the system optimizes fiber paths to minimize curvature, thereby transforming the curvature parameter from a harmful factor into a controlled design parameter that prevents defects.
Data Source
AI summary
A method of planning fiber paths for a composite ply of a composite layup includes determining a first unit vector field. The first unit vector field represents a first approximation of target directions to be followed by tow centerlines of the composite ply. The first unit vector field is determined based on a specified rosette direction, a surface approximation of a nonplanar contoured surface of an object to be formed, and a fiber angle distribution. The method also includes determining, based on specified angle deviation bounds and the first unit vector field, a second unit vector field. The second unit vector field represents a second approximation of the target directions. The second approximation has reduced in-plane curvature relative to the first approximation. The method further includes planning a fiber placement head path for forming the composite ply of the composite layup based on the second unit vector field.