Correction Factor Approach for Enhanced Intimate Contact Prediction in Laser-Assisted Fiber Placement Process
Topic(s) : Manufacturing
Co-authors :
Mehmet YILDIZ , Sasan KARIMI (TURKEY), Hatice HATICE S. SAS (TURKEY)Abstract :
In the manufacturing of advanced composite materials, Automated Fiber Placement (AFP) has become an innovative method that uses robotic systems to precisely place high-strength fibers on a substrate. AFP is vital for creating complex components for aerospace and automotive applications because of its automated process, which guarantees precision, efficiency, and the most effective possible utilization of materials. Enhancing the efficiency of advanced composites manufacturing processes is possible through the AFP process by incorporating high-performance thermoplastic resin systems, such as Polyether Ether Ketone (PEEK), Polyether Ketone Ketone (PEKK), Polyphenylene Sulfide (PPS), and Polyetherimide (PEI). Shorter processing times, improved component consolidation, and higher damage tolerance are achieved by employing the AFP method with these thermoplastic resin systems, which are known for their outstanding mechanical qualities, chemical resistance, and recyclability.
Laser-Assisted Fiber Placement (LAFP), which integrates laser technology to enhance temperature control during the manufacturing process, takes center stage as AFP develops. By allowing for more precise heating and consolidation, the incorporation of lasers to LAFP improves the bonding between fibers and the matrix and enhances material characteristics. In the context of Laser-Assisted Fiber Placement (LAFP), achieving intimate contact is a crucial factor. Reaching intimate contact not only improves bonding but also minimizes voids, ensuring the creation of an efficient and coherent composite structure. Furthermore, intimate contact can influence the temperature profile in heat transfer analysis, thereby affecting process modeling, including the accurate prediction of degree of bonding.
Numerous models have been proposed in literature because of an understanding of the importance of intimate contact. One notable illustration of an intimate contact model is the Mantell and Springer model; however, it has been demonstrated that it has some drawbacks, such as underestimating and neglecting to consider fiber orientation into account. In response, a correction factor for the Mantell and Springer intimate contact model is introduced in this study. The fiber orientation and the LAFP process parameters (placement speed and consolidation force) are taken into consideration by this correction factor. Henceforth, this modification will be called the modified MS model, or MMS for short. The MMS model is validated using literature, demonstrating that the modified model can predict the degree of intimate contact with high accuracy.
Laser-Assisted Fiber Placement (LAFP), which integrates laser technology to enhance temperature control during the manufacturing process, takes center stage as AFP develops. By allowing for more precise heating and consolidation, the incorporation of lasers to LAFP improves the bonding between fibers and the matrix and enhances material characteristics. In the context of Laser-Assisted Fiber Placement (LAFP), achieving intimate contact is a crucial factor. Reaching intimate contact not only improves bonding but also minimizes voids, ensuring the creation of an efficient and coherent composite structure. Furthermore, intimate contact can influence the temperature profile in heat transfer analysis, thereby affecting process modeling, including the accurate prediction of degree of bonding.
Numerous models have been proposed in literature because of an understanding of the importance of intimate contact. One notable illustration of an intimate contact model is the Mantell and Springer model; however, it has been demonstrated that it has some drawbacks, such as underestimating and neglecting to consider fiber orientation into account. In response, a correction factor for the Mantell and Springer intimate contact model is introduced in this study. The fiber orientation and the LAFP process parameters (placement speed and consolidation force) are taken into consideration by this correction factor. Henceforth, this modification will be called the modified MS model, or MMS for short. The MMS model is validated using literature, demonstrating that the modified model can predict the degree of intimate contact with high accuracy.