Integrated Design and Manufacturing Analysis for Automated Fiber Placement Structures

Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed Central Optimizer tool will be used to tie the modules together and drive the design for manufacturing process

Automated Fiber Placement Defect Identity Cards: Cause, Anticipation, Existence, Significance, and Progression

Automated Fiber Placement (AFP), a major composite manufacturing process, can result in many defects during the layup process that often require manual corrective action to produce a part with acceptable quality. These defects are the main limitation of the technology and can be hard to categorize or define in many situations. This paper provides a thorough definition and classification of all AFP defects. This effort constitutes a comprehensive and extensive library relevant to AFP defects. The defects selected and defined in this work are based on understanding and experience from the manufacture and research of advanced composite structure. Proper classification of these defects required an in-depth literature review and consideration of various viewpoints ranging from designers, manufacturers, analysts, and inspection professionals. Collectively, these sources were utilized to develop the most accurate view of each of the individual defect types. The results are presented as identity cards for each defect type, intended to provide researchers and the manufacturing industry a clear understanding of the (1) cause, (2) anticipation, (3) existence, (4) significance, and (5) progression of the defined AFP defects. The link between AFP defects and process planning, layup strategies, and machining was also investigated. Categorization of all important automated fiber placement defects is presented

Characterization of Prepreg Tack for Composite Manufacturing by Automated Fiber Placement

Automated fiber placement (AFP) has become the industry standard for large-scale production of carbon fiber reinforced plastics (CFRP) to improve rate and reduce defects associated with manual layup. Still, defects generated during AFP processes require manual, painstaking inspection by technicians and rework of the part when substantial defects are found. Prepreg (carbon fiber infused with uncured epoxy resin) tack is one of the primary factors that influences the generation of defects that arise during auto-mated fiber placement (AFP). Tack, as it relates to AFP processes and defect formation, can be understood as a combination of two stages, cohesion and decohesion. During the cohesion phase, two pieces of prepreg are brought into contact under elevated temperature and pressure. Compaction of the resin within the contact area will result in a degree of intimate contact, I, between the mating prepreg surfaces. Defect formation, as a result of decohesion between prepreg surfaces, occurs after the cohesion phase and arises due to stress from events such as fiber placement over an existing defect, on a contoured path, etc. (Figure 1). Tack strength resists the displacement of prepreg on a surface due to stresses developed during deposition

ISAAC - A Testbed for Advanced Composites Research

The NASA Langley Research Center is acquiring a state-of-art composites fabrication environment to support the Center's research and technology development mission. This overall system described in this paper is named ISAAC, or Integrated Structural Assembly of Advanced Composites. ISAAC's initial operational capability is a commercial robotic automated fiber placement system from Electroimpact, Inc. that consists of a multi-degree of freedom commercial robot platform, a tool changer mechanism, and a specialized automated fiber placement end effector. Examples are presented of how development of advanced composite materials, structures, fabrication processes and technology are enabled by utilizing the fiber placement end effector directly or with appropriate modifications. Alternatively, end effectors with different capabilities may either be bought or developed with NASA's partners in industry and academia

Advanced fiber placement of composite fuselage structures

The Hercules/NASA Advanced Composite Technology (ACT) program will demonstrate the low cost potential of the automated fiber placement process. The Hercules fiber placement machine was developed for cost effective production of composite aircraft structures. The process uses a low cost prepreg tow material form and achieves equivalent laminate properties to structures fabricated with prepreg tape layup. Fiber placement demonstrations planned for the Hercules/NASA program include fabrication of stiffened test panels which represent crown, keel, and window belt segments of a typical transport aircraft fuselage

Automation of Process Planning for Automated Fiber Placement

Process planning represents an essential stage of the Automated Fiber Placement (AFP) workflow. It develops useful and efficient machine processes based upon the working material, composite design, and manufacturing resources. The current state of process planning requires a high degree of interaction from the process planner and could greatly benefit from increased automation. Therefore, a list of key steps and functions are created to identify the more difficult and time-consuming phases of process planning. Additionally, a set of metrics must exist by which to evaluate the effectiveness of the manufactured laminate from the machine code created during the Process Planning stage. This work begins with a ranking process which was performed through a survey of the Advanced Composites Consortium (ACC) Collaborative Research Team (CRT). Members were interviewed who possessed practical process planning experience in the composites industry. The Process Planning survey collected general input on the overall importance and time requirements for each function and which functions would benefit most greatly from semi-automation or full automation. Layup strategies, in addition to dog ears, stagger shifts, steering constraints, and starting points, represented the group of functions labeled as process optimization and ranked the highest in terms of priority for automation. The laminates resulting from the selected parameters are evaluated through the occurrences of principal defect metrics such as fiber gaps, overlaps, angle deviation and steering violations. This document presents an automated software solution to the layup strategy and starting point selection phase of Process Planning. A series of ply scenarios are generated with variations of these ply parameters and evaluated according to a set of metrics entered by the Process Planner. These metrics are generated through use of the Analytical Hierarchy Process (AHP), where relative importance between each of the fiber features are defined. The ply scenarios are selected which reduce the overall fiber feature scores based on the defects the Process Planner wishes to minimize

Gap and Overlap Detection in Automated Fiber Placement

The identification and correction of manufacturing defects, particularly gaps and overlaps, are crucial for ensuring high-quality composite parts produced through Automated Fiber Placement (AFP). These imperfections are the most commonly observed issues that can significantly impact the overall quality of the composite parts. Manual inspection is both time-consuming and labor-intensive, making it an inefficient approach. To overcome this challenge, the implementation of an automated defect detection system serves as the optimal solution. In this paper, we introduce a novel method that uses an Optical Coherence Tomography (OCT) sensor and computer vision techniques to detect and locate gaps and overlaps in composite parts. Our approach involves generating a depth map image of the composite surface that highlights the elevation of composite tapes (or tows) on the surface. By detecting the boundaries of each tow, our algorithm can compare consecutive tows and identify gaps or overlaps that may exist between them. Any gaps or overlaps exceeding a predefined tolerance threshold are considered manufacturing defects. To evaluate the performance of our approach, we compare the detected defects with the ground truth annotated by experts. The results demonstrate a high level of accuracy and efficiency in gap and overlap segmentation