Automated Fiber Placement (AFP) has become a key technique for manufacturing lightweight, high-strength carbon fiber-reinforced polymer (CFRP) structures for aerospace applications. Precise control of process parameters, particularly lay-up force, is crucial for achieving high-quality placement and optimal mechanical properties. However, due to the complex interaction between the flexible roller and irregular mold surfaces, understanding pressure distribution during lay-up is challenging. This study develops a constitutive model for the roller and laminate and analyzes the roller-mold contact. Lay-up force is continuously adjusted to maintain the contact center pressure within the Optimal Pressure Range (OPR). To achieve real-time control, the roller cylinder’s dynamic characteristics were analyzed, and sliding mode control of the lay-up force was implemented by regulating input air pressure. Experimental results demonstrated the effectiveness of this approach, reducing pressure fluctuation residuals by 67.92%. The adjusted lay-up force maintained consistent pressure throughout the AFP process, significantly lowering defect risks compared to using a constant lay-up force.
SreejithMRajeevRS. 25 - fiber reinforced composites for aerospace and sports applications. In: JosephKOksmanKGeorgeG, et al. (eds) Woodhead publishing series in composites science and engineering. Cambridge: Woodhead Publishing, 2021, pp. 821–859. DOI: 10.1016/B978-0-12-821090-1.00023-5.
2.
AirAGangadhara PrustyB. Manufacturing feasibility of a bend free ellipsoidal composite pressure vessel using automated fibre placement. Compos Part A Appl Sci Manuf2024; 177: 107968. DOI: 10.1016/j.compositesa.2023.107968.
3.
MayerMSchusterABrandtL, et al.Integral quality assurance method for a CFRP aircraft fuselage skin: gap and overlap measurement for thermoplastic AFP BT. In: SilvaFJGPereiraABCampilhoRDSG (eds) Flexible automation and intelligent manufacturing: establishing bridges for more sustainable manufacturing systems. Cham: Springer Nature Switzerland, 2024, pp. 525–534.
4.
CastilloDSMartinIRodriguez-LenceF, et al.On-line monitoring of a laser-Assisted fiber placement process with CFR thermoplastic matrix by using Fiber Bragg Gratings. In: 8th European workshop on structural health monitoring (EWSHM 2016), Bilbao, Spain, 5–8 July 2016, 4, 3009–3018.
5.
RajanSSuttonMAWehbeR, et al.Experimental investigation of prepreg slit tape wrinkling during automated fiber placement process using StereoDIC. Composites Part B2019; 160: 546–557. DOI: 10.1016/j.compositesb.2018.12.017.
6.
CroftKLessardLPasiniD, et al.Experimental study of the effect of automated fiber placement induced defects on performance of composite laminates. Compos Part A Appl Sci Manuf2011; 42: 484–491. DOI: 10.1016/j.compositesa.2011.01.007.
7.
VenkatesanCZulkifliFSilvaA. Effects of processing parameters of infrared-based automated fiber placement on mechanical performance of carbon fiber-reinforced thermoplastic composite. Compos Struct2023; 309: 116725. DOI: 10.1016/j.compstruct.2023.116725.
8.
AizedTShirinzadehB. Robotic fiber placement process analysis and optimization using response surface method. Int J Adv Manuf Technol2011; 55: 393–404. DOI: 10.1007/s00170-010-3028-1.
9.
Aghababaei TafreshiOVan HoaSShadmehriF, et al.Determination of convective heat transfer coefficient for automated fiber placement (AFP) for thermoplastic composites using hot gas torch. Adv Manuf Polym Compos Sci2020; 6: 86–100. DOI: 10.1080/20550340.2020.1764236.
10.
KhanMAMitschangPSchledjewskiR. Parametric study on processing parameters and resulting part quality through thermoplastic tape placement process. J Compos Mater2013; 47: 485–499. DOI: 10.1177/0021998312441810.
11.
BakhshiNHojjatiM. Effect of compaction roller on layup quality and defects formation in automated fiber placement. J Reinforc Plast Compos2020; 39: 3–20. DOI: 10.1177/0731684419868845.
12.
LukaszewiczDHJAWardCPotterKD. The engineering aspects of automated prepreg layup: history, present and future. Composites Part B2012; 43: 997–1009. DOI: 10.1016/j.compositesb.2011.12.003.
13.
CrossleyRJSchubelPJWarriorNA. The experimental determination of prepreg tack and dynamic stiffness. Compos Part A Appl Sci Manuf2012; 43: 423–434. DOI: 10.1016/j.compositesa.2011.10.014.
14.
DenkenaBSchmidtCVöltzerK, et al.Thermographic online monitoring system for automated fiber placement processes. Composites Part B2016; 97: 239–243. DOI: 10.1016/j.compositesb.2016.04.076.
15.
ZacchiaTTShadmehriFFortin-SimpsonJ, et al.Design of hard compaction rollers for automated fiber placement on complex mandrel geometries. In: Proceedings of the Canadian Society for Mechanical Engineering International Congress,Toronto, ON, Canada, 2018, pp. 1–4. DOI: 10.25071/10315/35245.
16.
BrasingtonASaccoCHalbritterJ, et al.Automated fiber placement: a review of history, current technologies, and future paths forward. Compos Part C Open Access2021; 6: 100182. DOI: 10.1016/j.jcomc.2021.100182.
17.
EndruweitAGhoseSJohnsonBA, et al.Tack testing to aid optimisation of process parameters for automated material placement in an industrial environment. In: ICCM international conference on composite materials, Xi'an, China, 20–25 August 2017, 20–25.
18.
EndruweitAChoongGYHGhoseS, et al.Characterisation of tack for uni-directional prepreg tape employing a continuous application-and-peel test method. Compos Part A Appl Sci Manuf2018; 114: 295–306. DOI: 10.1016/j.compositesa.2018.08.027.
19.
BudelmannDDetampelHSchmidtC, et al.Interaction of process parameters and material properties with regard to prepreg tack in automated lay-up and draping processes. Compos Part A Appl Sci Manuf2019; 117: 308–316. DOI: 10.1016/j.compositesa.2018.12.001.
20.
WangYMahapatraSBelnoue JP-H, et al.Modelling the effect of process conditions on steering-induced defects in automated fibre placement (AFP). Compos Part A Appl Sci Manuf2023; 173: 107702. DOI: 10.1016/j.compositesa.2023.107702.
21.
SchmidtCDenkenaBHockeT, et al.Influence of AFP process parameters on the temperature distribution used for thermal in-process monitoring. Procedia CIRP2017; 66: 68–73. DOI: 10.1016/j.procir.2017.03.220.
22.
OromiehieEPrustyBGCompstonP, et al.The influence of consolidation force on the performance of AFP manufactured laminates. In: ICCM international conference on composite materials, Xi'an, China, 20–25 August 2017.
MiaoQDaiZMaG, et al.Effect of consolidation force on interlaminar shear strength of CF/PEEK laminates manufactured by laser-assisted forming. Compos Struct2021; 266: 113779. DOI: 10.1016/j.compstruct.2021.113779.
25.
ZhangCDuanYXiaoH, et al.The effects of processing parameters on the wedge peel strength of CF/PEEK laminates manufactured using a laser tape placement process. Int J Adv Manuf Technol2022; 120: 7251–7262. DOI: 10.1007/s00170-022-09181-5.
26.
MathewEJoshiSC. Effect of roller pressure and base prepreg layer on tensile and flexural properties of CFRP laminates fabricated using automated fiber placement. J Compos Sci2023; 7: 101. DOI: 10.3390/jcs7030101.
27.
JiangJHeYWangH, et al.Modeling and experimental validation of compaction pressure distribution for automated fiber placement. Compos Struct2021; 256: 113101. DOI: 10.1016/j.compstruct.2020.113101.
28.
MiaoLZhuWGuoY, et al.An analytical model for pressure distribution in automated fiber placement on irregular surfaces and its application in aeronautical manufacturing. J Manuf Process2023; 106: 102–116. DOI: 10.1016/j.jmapro.2023.09.057.
29.
ChengLZhengCWangH, et al.Pressure control for pneumatic pressing roller in automated fiber placement. J Reinforc Plast Compos2023; 43: 1323–1339. DOI: 10.1177/07316844231205077.
30.
GentAN. Engineering with rubber: how to design rubber components. Germany: Carl Hanser Verlag GmbH Co KG, 2012.
31.
YükselerRF. Local and nonlocal buckling of Mooney-Rivlin rods. Eur J Mech2019; 78: 103816.
32.
FreakleyPKPayneARDaveyAB. Theory and practice of engineering with rubber. London: Applied Science Publishers, 1978.
33.
HeYJiangJQuW, et al.Compaction pressure distribution and pressure uniformity of segmented rollers for automated fiber placement. J Reinforc Plast Compos2022; 41: 427–443.
34.
ISO 7743:2017. Rubber, vulcanized or thermoplastic—Determination of compression stress-strain properties. Geneva: International Organization for Standardization, 2017.
35.
LukaszewiczDHJAPotterK. Through-thickness compression response of uncured prepreg during manufacture by automated layup. Proc Inst Mech Eng Part B J Eng Manuf2012; 226: 193–202.
36.
TaheriBCaseDRicherE. Force and stiffness backstepping-sliding mode controller for pneumatic cylinders. IEEE ASME Trans Mechatron2014; 19: 1799–1809.
37.
DriverTShenX. Pressure estimation-based robust force control of pneumatic actuators. Int J Fluid Power2013; 14: 37–45.
38.
XuXChengLGuoY, et al. A modeling and calibration method of heavy-duty automated fiber placement robot considering compliance and joint-dependent errors. J Mech Robot. 2023; 15(6): 061011. doi:10.1115/1.4056405.
39.
XuXChengLMiaoL, et al.End-effector contact force estimation for the industrial robot in automated fiber placement processes with dynamic end-load variations. CIRP J Manuf Sci Technol2024; 55: 390–402.
