Abstract
To investigate the mechanism of the effect of process parameters on bubble flow behavior during automated fiber placement (AFP) and the relationship between the bubble and voids, mechanical properties of laminates, this paper analyzes the multiphase flow coupling behavior of the bubble and fiber formation using computational fluid dynamics (CFD) and finite element (FE) method under different AFP process parameters. The effects of AFP process parameters on bubble characteristics and fiber deformation are then discussed, respectively, including bubble displacement, maximum cross‐sectional area, the lowest internal temperature of the bubble, bubble breakup, and maximum deformation of the fiber. Furthermore, the AFP and corresponding test experiments are performed to investigate the relationships between different bubble characteristics and void content, mechanical properties, mainly interlaminar shear strength (ILSS) and flexural strength (FS). The results show that the maximum cross‐sectional area of bubbles is closely related to the AFP process parameters. The FS and ILSS are positively correlated with the maximum cross‐sectional area. With the increase of bubble displacement and fiber maximum deformation, FS and ILSS are first increased and then decreased.
Highlights
Fiber Reinforced Plastics/composites (FRPs) have been widely used for many years in the aerospace, naval, automotive, and civil applications due to their several advantages over traditional materials, such as high stiffness and strength to weight ratio, more excellent fatigue resistance, better long-term durability, lower thermal expansion and superior corrosion resistance [1,2,3,4]
To aid in such an understanding, this paper investigates the relationship between the bubble behaviors and the automated fiber placement (AFP) process parameters, void content, and mechanical properties using computational fluid dynamics (CFD) and finite element (FE) method
The laying speed is opposite to that, which has a positive correlation with the cross-sectional area of the bubble
Summary
Fiber Reinforced Plastics/composites (FRPs) have been widely used for many years in the aerospace, naval, automotive, and civil applications due to their several advantages over traditional materials (e.g., metals), such as high stiffness and strength to weight ratio, more excellent fatigue resistance, better long-term durability, lower thermal expansion and superior corrosion resistance [1,2,3,4]. Among them, automated fiber placement (AFP) appeared in the 1970s in the aerospace industry It combines the advantages of filament winding and automated tape laying to overcome their limitations and exploit their benefits, which is one of the fastest-growing and most effective fully automated manufacturing technologies for composite materials in recent years [9,10,11,12]. E results indicate that obvious gradients in final void content exist through the thickness and are closely related to processing parameters including the heating temperature, laying speed, and heater height. It is difficult to understand the mechanism of controlling defects in process optimization To aid in such an understanding, this paper investigates the relationship between the bubble behaviors and the AFP process parameters, void content, and mechanical properties using computational fluid dynamics (CFD) and finite element (FE) method. The AFP and testing experiments are performed to reveal the relationship between void content, mechanical properties, and bubble characteristics
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