Predicting and Improving Interlaminar Bonding Uniformity during the Robotic Fiber Steering Process

Area of Science:

• Materials Science
• Composite Materials Engineering
• Manufacturing Processes

Background:

• Fiber-reinforced resin matrix composites offer high specific stiffness and corrosion resistance, crucial for aerospace, marine, and automotive applications.
• Defect minimization is key to reducing the high cost of composite component fabrication.
• Fiber steering, while enabling complex shapes and enhanced properties, introduces defects like fiber waviness and uneven interlaminar bonding.

Purpose of the Study:

• To reduce fiber waviness and improve interlaminar bonding uniformity during the fiber steering process.
• To investigate the impact of fiber steering parameters on defect generation.
• To optimize the fiber placement process for enhanced composite part quality.

Main Methods:

• Utilized a multi-piece compaction roller to address fiber waviness and interlaminar bonding issues.
• Analyzed the underlying mechanisms of fiber waviness generation during fiber steering.
• Conducted experiments to investigate interlaminar bonding strength variations across the tow width.
• Optimized key process parameters including compaction force, laying temperature, and laying velocity.

Main Results:

• Successfully reduced fiber waviness through the application of the multi-piece compaction roller.
• Achieved improved uniformity in interlaminar bonding strength along the path width.
• Demonstrated the effectiveness of optimizing compaction force, laying temperature, and velocity.

Conclusions:

• The multi-piece compaction roller is an effective solution for mitigating fiber waviness and enhancing interlaminar bond uniformity in fiber steering.
• Optimizing process parameters is crucial for improving the dimensional accuracy and mechanical performance of composite parts.
• This research contributes to more reliable and cost-effective manufacturing of high-performance composite components.