Effect of Manufacturing Signatures on the optimal fiberpaths for doubly-curved, open surfaces manufactured using Automated Fiber Placement

  • Savin, Egor (University of Washington)
  • A. Vijayachandran, Avinkrishnan (University of Washington)

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As the aerospace industry has widely adopted composite-based aircraft structures, Automated Fiber Placement (AFP) has been widely incorporated as high throughput manufacturing technology for such structures because of its accuracy and repeatability. However, most current applications rely on straight fiber paths, which can be arguably overdesigned in terms of structural performance. Using curvilinear fiber paths will improve structural behavior by allowing a better distribution of material stiffness, but their use is limited by manufacturing constraints, including the inherent drawback of creating more defects. This work presents a computational approach to designing curvilinear fiber paths that are amenable to AFP-based manufacturing of doubly-curved open surfaces. A Python-based tool is developed to generate AFP models by offsetting an initial fiber path defined as a B´ ezier spline on a given surface. Important manufacturing features, such as fiber width, fiber path, radii of curvature, and the formation of gaps and overlaps, are explicitly considered. Steering radius is the main constraint and the actual value of constraint may vary significantly, depending on the path algorithm chosen, curvature of the tool, in addi- tion to course width and material properties1. Although the full implementation of curvature constraints remains challenging, particularly for curved surfaces, their integration is an active part of the ongoing development. This ensures that the generated fiber layouts are not only mathematically valid but also manufacturable. The generated fiber layouts are used in numerical models to perform nonlinear stability analysis using a commercial finite element software, Abaqus. As a proof of concept, a slightly curved, composite plate with clamped loading edges and simply supported lateral edges is analyzed. First, an optimal straight- fiber configuration is identified and used as a reference. The curvilinear fiber paths are then explored using the proposed method. The results show an increase in the critical buckling load compared to the straight-fiber case, without a significant increase in structural mass. The effect of changing manufactur- ing parameters on the optimal results will also be explored. The proposed approach is general and can be extended to more complex structures, such as plates with cut-outs, cylindrical shells, and curved surfaces.