Fiber Trajectory Definition Using Constraint Grids
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Solution Overview
Problem
Current methods for defining fiber trajectories on layup surfaces for composite material parts are time-consuming and tedious, especially for complex or non-continuous surfaces, requiring lengthy manual adjustments to achieve acceptable radii of curvature and angular deviations.
Innovation Solution
A method that defines fiber trajectories by using constraint curves and constraint grids, incorporating geometric, curvature, and stress constraints through normalized weights, allowing for automated software implementation and reducing the time required for trajectory definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rosette-based transfer methods are used to define fiber trajectories, then fiber direction can be defined on all points of the surface, but calculation time becomes relatively long particularly for complex surfaces
Solution Approach 1:
The patent segments the continuous surface into discrete triangular elements forming a mesh. Each triangle's vertices serve as propagation points where fiber directions are independently calculated using the rosette method. This segmentation allows parallel processing of multiple points and reduces the computational burden compared to calculating continuous trajectories across the entire surface.
Solution Approach 2:
The patent performs preliminary calculation of fiber directions at all propagation points (triangle vertices) before actual trajectory generation. The rosette method is applied in advance to determine the orientation of fibers at each vertex, and these pre-calculated directions are then used to construct the complete trajectories by connecting the vertices. This preliminary action separates the complex directional calculation from the trajectory tracing process.
2Manufacturing precision
If manual adjustment of trajectories is performed to achieve acceptable radii of curvature and angular deviations, then manufacturing constraints are satisfied, but the process becomes long and tedious
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an automated computational system. The software automatically calculates fiber directions using the rosette method at each propagation point and generates trajectories that inherently satisfy manufacturing constraints. The system computes radii of curvature and angular deviations algorithmically, eliminating the need for iterative manual adjustments while maintaining precision.
Solution Approach 2:
The patent implements a feedback mechanism where the software continuously evaluates trajectory parameters (radii of curvature, angular deviations) against manufacturing constraints during the automated generation process. If constraints are not satisfied, the system automatically adjusts the trajectory calculation rather than requiring manual intervention. This closed-loop feedback ensures constraint satisfaction while maintaining efficiency.
3Adaptability or versatility
If trajectories are defined for non-continuous layup surfaces with recesses and embossments, then complex geometric features can be accommodated, but the definition process becomes complicated and requires lengthy manual operations
Solution Approach 1:
The patent segments the complex non-continuous surface into a mesh of triangular elements, with each triangle representing a local planar region. This segmentation simplifies the handling of complex geometries by breaking them down into manageable units where the rosette method can be uniformly applied at each vertex, regardless of the overall surface complexity.
Solution Approach 2:
The patent introduces a computational dimension by representing the three-dimensional complex surface as a two-dimensional mesh of triangular elements with associated vertex coordinates. This dimensional transformation allows the application of planar rosette methods at each vertex while accommodating the three-dimensional complexity of the overall surface geometry, including recesses and embossments.
Data Source
AI summary
A method for defining trajectories of fibers on a layup surface for producing at least one ply having a given theoretical orientation, by laying up fibers, including the steps of providing the definition of the constraint curves and/or the definition of at least one constraint grid with association of at least one constraint vector to each node of the constraint grid, the direction of a fiber at an analysis point of the layup surface, being obtained by calculation of the normalized weights of the constraint vectors of the constraint curves and/or by calculation by of the normalized weights of the constraint vectors of the constraint grid, and by weighting by the normalized weights of the constraint vectors.