Abstract
This paper presents an effective process optimization methodology for laser assisted tape winding (LATW) of complex part geometries by means of a numerical optical-thermal model. A winding path on the cylindrical and ellipsoidal (dome) part of a pressure vessel is considered with varying tooling curvature. First, the process model output is verified with the literature data based on the laser intensity distribution. Then, the transient laser irradiation and temperature distributions on the tape and substrate are described comprehensively. It is shown that the maximum laser intensity increases approximately by 80% and the process (bonding) temperature changes by 80 °C at the intersection of the cylindrical and dome section of the pressure vessel. In order to keep the transient process temperature constant, a robust optimization scheme is utilized by means of a genetic algorithm. The design variable is determined as the total laser power and temperature constraints are defined. The proposed optimization methodology regulates the temperature within 1.5 °C variation with respect to the desired value. In order to compensate the transient local curvature effects on the process temperature, the total laser power varies approximately between 30% and 175% of the reference (non-optimized) case.
Highlights
Laser assisted tape winding (LATW) and placement (LATP) are automated manufacturing techniques to produce high performance fiber reinforced thermoplastic (FRTP) composite parts
This paper presents an effective process optimization methodology for laser assisted tape winding (LATW) of complex part geometries by means of a numerical optical-thermal model
A transient optical-thermal process model was developed which was used in a single objective problem
Summary
Laser assisted tape winding (LATW) and placement (LATP) are automated manufacturing techniques to produce high performance fiber reinforced thermoplastic (FRTP) composite parts. The incoming thermoplastic composite prepreg tape and already wound substrate or tooling are heated using a laser source and bonded under the application of a pressure exerted by a compaction roller in LATW processes [7]. The control of the bonding temperature is a difficult task especially during deposition of composite layers on a curved surface with curvilinear fiber paths such as the cylindrical and dome parts of pressure vessels. Due to the change in the local curvature during winding or placing FRTP tapes on complex geometries, e.g. dome part of a pressure vessel, the process temperature changes and an unsteady thermal history is present [14]. Comprehensive temperature control approaches are needed to minimize the temperature variation and keep the process temperature within the desired target temperature boundaries
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