Fiber Tow Path Planning for Tight-Curve Composite Forming
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Solution Overview
Problem
Current methods for manufacturing fiber-reinforced plastic composite objects using fiber tows face challenges in analyzing, segmenting, and planning the application of these narrower and thicker fibers, especially when forming tight curves and diverse fiber layout patterns, and in adjusting for compression molding distortions.
Innovation Solution
A computer-implemented method and system that decomposes a digital model into surface-based component models, forms paths for elongate fiber tows, and uses a pressure foot device with a groove to guide and rotate the tows, allowing for the formation of tight curves and diverse patterns, while also simulating compression molding processes to adjust designs and paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If fiber tows are used instead of fiber tapes, then the ability to form tight curves is improved, but the device complexity increases due to the need for specialized pressure foot devices
Solution Approach 1:
The pressure foot device is segmented into a body and a rotatable groove component, allowing the groove to be independently rotated to guide fiber tows along curved paths while keeping the overall device structure manageable
Solution Approach 2:
The groove acts as an intermediary element between the pressure foot device and the fiber tow, enabling the tow to follow curved trajectories by being guided and rotated within the groove structure
2Manufacturing precision
If a rotatable pressure foot device is used to form tight curves, then the manufacturing precision of curved paths is improved, but the ease of operation deteriorates due to rotation control requirements
Solution Approach 1:
The system incorporates feedback mechanisms where the groove's rotation and the pressure foot device's movement are controlled based on pre-planned paths, ensuring that the fiber tow is deposited with high precision along the desired curved trajectory
Solution Approach 2:
The paths for fiber tow deposition are planned and programmed in advance, allowing the rotatable groove and pressure foot device to follow predetermined trajectories, thereby simplifying real-time operation while maintaining high manufacturing precision
3Reliability
If compression molding simulation is performed, then the reliability of the manufacturing process is improved, but the loss of time increases due to additional simulation steps
Solution Approach 1:
Compression molding simulation is performed in advance during the path planning stage, allowing potential issues with fiber tow deformation and distortion to be identified and corrected before actual manufacturing, thereby improving process reliability without delaying production
Solution Approach 2:
A digital model of the fiber-reinforced object is created and used for simulation, allowing virtual testing of compression molding effects on fiber paths without requiring physical prototypes or trial runs, thus reducing time loss while enhancing reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient planning and formation of complex fiber-reinforced plastic composite objects with improved fiber layout and reduced distortion, enhancing the manufacturing process by allowing for precise control over fiber placement and simulation of molding processes.
Implementation Method 1
The pressure foot device is rotatable around an axis, for example an axis orthogonal to the surface of the object. The method for forming tight curves comprises, for example, rotating the pressure foot device that comprises a groove for one or more of guiding and rotating the tow onto the surface of an object.
Data Source
AI summary
A computer-implemented method comprising, under the control of one or more computer systems or non-volatile storage medium configured with executable instructions: acquiring a digital model comprising two or more spatial dimensions of an object to be manufactured; forming a three-dimensional model decomposition of the object to be manufactured, wherein forming the three-dimensional model decomposition comprises segmenting at least a portion of the digital model comprising two or more spatial dimensions into one or more surface-based component models; and forming, on one or more surfaces of the one or more surface-based component models, one or more paths comprising one or more elongate fiber tow models.