Fiber Preform Cutting Pattern Optimization
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Solution Overview
Problem
In large-scale production of fiber composite components, the existing methods for producing multiaxial non-crimp fabrics result in significant material waste, which increases production costs due to the inefficiency of cutting and laying individual fiber strips to achieve the desired geometry and contour.
Innovation Solution
A method and device that generate a cutting pattern for fiber preforms by subdividing the geometry into partial elements, optimizing their arrangement and cutting to minimize waste, using a computer-aided optimization process to determine the optimal cutting pattern that reduces excess material and arranges fiber strips with coordinated cutting angles and edges to minimize material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual fiber strips are cut and laid one after another to produce fiber preforms with specific geometry, then manufacturing precision and adaptability are improved, but productivity is significantly reduced
Solution Approach 1:
The fiber preform geometry is divided into multiple partial elements that can be arranged in different sequences. This segmentation allows the cutting device to process multiple strips simultaneously or in optimized sequences, improving productivity while maintaining geometric precision through computer-aided optimization of the cutting pattern.
2Productivity
If multiaxial non-crimp fabrics are produced as yard goods with constant width, then productivity is improved, but material waste increases significantly
Solution Approach 1:
A cutting pattern is generated in advance using computer-aided optimization, calculating the optimal arrangement of partial elements before cutting begins. This preliminary planning ensures that fiber strips are cut and laid in an optimized sequence that minimizes material waste while maintaining high productivity, avoiding the need to produce excess yard goods that must be subsequently cut and discarded.
3Loss of substance
If fiber strips are cut to specific shapes and assembled individually, then manufacturing precision and waste reduction are improved, but device complexity increases
Solution Approach 1:
A microprocessor-controlled pattern determination unit serves as an intermediary between the design geometry and the cutting device. This computer-aided system generates optimized cutting patterns that minimize material waste, translating complex geometric requirements into actionable cutting instructions without requiring overly complex mechanical cutting mechanisms.
Data Source
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AI summary
The invention relates to a method and a system for producing a fiber preform for manufacturing a fiber composite component, wherein the geometry of the fiber preform is divided into a plurality of sub-elements and subsequently an arrangement of the individual sub-elements on a fiber material is determined such that the generated cutting pattern is optimized with regard to material waste. The sub-elements are then cut according to the cutting pattern and the individual sub-elements are laid down to form the fiber preform.