AFP tool path planning for manufacture of variable stiffness composites

Abstract

Variable stiffness composites (VSC) demonstrate enhanced mechanical properties compared to conventional carbon fiber reinforced plastics (CFRP). Finite element analysis (FEA) is used to optimize layup directions, which need to be transformed into viable tool paths for automated fiber placement (AFP) processes. Manufacturing defects such as wrinkles, gaps, and overlaps should be handled. In this study, a novel path planning algorithm is developed for variable steering in AFP. The fiber directions are clustered and for each cluster a reference curve is fitted as B-Spline, where manufacturing constraints are considered. The proposed tool path planning approach is successfully demonstrated in a case study.