Steered Fiber Orientations in Thermoplastic Composite Stamp Forming
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Solution Overview
Problem
Stamp forming of thermoplastic composite (TPC) parts with complex or sharp features faces challenges due to fiber orientation issues, leading to wrinkling or bunching, and limitations in load transfer and performance.
Innovation Solution
The method involves using automated fiber placement to steer prepreg fibers into desired orientations, allowing for the production of TPC parts with tailored fiber alignments, which are then consolidated and stamp formed to net-shape without wrinkling or bunching, enabling the creation of parts with complex shapes and small features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unidirectional fibers are used in TPC blanks for stamp forming, then manufacturing simplicity is maintained, but fiber orientation causes wrinkling or bunching in complex or sharp features
Solution Approach 1:
The patent applies local quality by transitioning from uniform unidirectional fiber orientation to locally tailored fiber orientations that vary across different regions of the TPC blank. The fiber placement is optimized for each local area to match the specific geometric features and forming requirements of that region, preventing wrinkling and bunching while maintaining manufacturing feasibility.
Solution Approach 2:
The patent implements dynamics by making fiber orientations adaptable and variable rather than fixed and uniform. The fiber placement system dynamically adjusts fiber directions based on the local geometry and forming conditions of different parts of the blank, allowing the fiber architecture to respond to specific forming challenges in complex or sharp features.
2Device complexity
If conventional fiber placement is used in TPC blanks, then production process is simple, but load transfer and part performance are limited
Solution Approach 1:
The patent enhances load transfer capability by implementing local quality in fiber placement, where fiber orientations are specifically tailored to match local stress and load paths in different regions of the part. This localized fiber alignment optimizes structural performance and load transfer efficiency without requiring a complete overhaul of the production process.
3Manufacturing precision
If fiber orientations are optimized for complex features, then forming quality improves, but fiber placement complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-planning and pre-positioning fiber orientations during the blank fabrication stage to anticipate and prevent forming defects. The fiber placement is designed in advance to accommodate complex features and forming operations, eliminating the need for complex adjustments during actual stamp forming and simplifying the forming process itself.
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
This approach facilitates the production of TPC parts with optimized fiber orientations, reducing product flow times and enhancing load transfer, making it suitable for high-rate production environments.
Implementation Method 1
heating the thermoplastic laminate to a temperature at which the thermoplastic laminate may be formed
Implementation Method 2
The near net-shape part is then re-melted and stamp formed to final net-shape
Data Source
AI summary
Thermoplastic composite parts are produced by automated fiber placement followed by stamp forming a layup having tailored fiber orientations. The tailored fiber orientations are achieved by tow steering and result in a layup that does not wrinkle during forming.