Experimental characterization and numerical simulation of the automated fiber placement (AFP) process for thermoplastic fiber-reinforced plastics

热塑性纤维增强塑料自动纤维铺放 (AFP) 工艺的实验表征和数值模拟

• 批准号: 325153381
• 负责人: Professor Dr.-Ing. Klaus Drechsler
• 金额: --
• 依托单位: Lehrstuhl für Carbon Composites
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/325153381?language=en
• 关键词: Experimental; characterization; numerical; simulation; automated

The efficient, high-quality and reproducible production of thermoplastic fiber-reinforced plastic components requires automated manufacturing processes. Due to its load-path oriented deposition of fibers to near-net-shape components, automated fiber placement (AFP) has particularly great potential. With proper temperature control during thermoplastic AFP (TP-AFP) in-situ consolidation is possible, i.e. a consolidation in place of the process without downstream thermosetting. However, the understanding of the process is still far from reaching the level of maturity necessary for a broad industrial application of TP-AFP. For example, it is still difficult today to define suitable process windows for the most important key parameters such as laser power, velocity and compaction pressure so that a consistently high quality of components is assured. In particular, the prediction of residual stresses and distortion is only solved insufficiently and process calibration is often based on a trial-and-error method. The reasons for this discrepancy between low prediction accuracy and high industrial demands can likewise be ascribed to possibilities of experimental characterization and modeling and simulation that are not yet maxed out. Therefore, the aim of the applicants is to improve process understanding in the area of TP-AFP fundamentally through novel experimental studies and methods of numerical simulation. On the experimental side, the focus will be on the integration of fiber optic sensors into the AFP process. For the first time, fiber Bragg grating (FBG) sensors will be used to monitor the characteristic TP-AFP process variables (consolidation pressure and laminate temperature) at key points, including within the laminate, thus allowing a reliable determination of the process-induced residual stresses subsequent to manufacturing. A long-term goal is the surveillance of the component in operation by so-called structure health monitoring (SHM). With respect to numerical simulation of the TP-AFP process, there is still a lack today of a holistic approach to reliably predict the critical component properties. Therefore, the focus in this project will be on the development and gradual integration of a corresponding overall process model based on nonlinear finite element methods (FEM). The aim is to achieve a significant improvement in prediction accuracy over the current state of research with this TP-AFP overall process model. Finally, the integration of experiment, modeling and simulation is also a particular feature of this project. For example, the simulation activities will consistently access the experimental results obtained in parallel so that all the sub-models can be appropriately parameterized. This integrated approach ultimately ensures the highest possible quality of the developed process model.

热塑性纤维增强塑料组件的有效，高质量和可重复的产生需要自动制造工艺。由于其面向纤维的负载路径为近网状成分的沉积，自动化纤维放置（AFP）具有特别巨大的潜力。在热塑性AFP（TP-AFP）原位合并过程中，可以进行适当的温度控制，即可以代替该工艺的合并而无需下游热固度。但是，对这一过程的理解远未达到TP-AFP的广泛工业应用所需的成熟度。例如，今天仍然很难为最重要的关键参数定义合适的过程窗口，例如激光功率，速度和压实压力，以确保始终高质量的组件。特别是，仅解决残留应力和失真的预测不足，并且过程校准通常基于试验方法。低预测准确性和高工业需求之间这种差异的原因同样可以归因于尚未最大化的实验表征，建模和模拟的可能性。因此，申请人的目的是通过新的实验研究和数值模拟方法从根本上提高TP-AFP领域的过程理解。在实验方面，焦点将放在光纤传感器中的集成到AFP过程中。首次将使用纤维Bragg光栅（FBG）传感器来监视关键点（包括在层压板）的特征性TP-AFP过程变量（合并压力和层压温度），从而可以可靠地确定该过程诱导的确定制造后的残余应力。一个长期目标是通过所谓的结构健康监测（SHM）对组件进行监视。关于TP-AFP过程的数值模拟，如今仍然缺乏可靠预测关键组件特性的整体方法。因此，该项目的重点将放在基于非线性有限元方法（FEM）的相应总体过程模型的开发和逐步集成上。目的是通过此TP-AFP总体过程模型在目前的研究状态上实现预测准确性的显着提高。最后，实验，建模和仿真的集成也是该项目的特定特征。例如，模拟活动将始终访问并行获得的实验结果，以便可以适当地将所有子模型进行参数化。这种集成的方法最终确保了开发过程模型的最高质量。