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Modelling gaps and overlaps for assessing the structural response of AFP composite structures by means of numerical simulation
Falk Heinecke and Tobias Wille,International Conference on Manufacturing of Advanced Composites ICMAC, 24-25 June 2015, Bristol, UK

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Within current composite part development and manufacturing processes a disproportional high effort is implied in order to find optimal process parameters and to meet required qualities and tolerances of high performance light weight structures. The ECOMISE project aims to enable next generation of thermoset composite manufacturing and post-processing. Within this project high precision process techniques for advanced dry fibre placement (AFP), infusion/ injection (RTI/ RTM) and curing will be developed in order to maximize process efficiency at reduced costs and production time due to less material consumption, higher reproducibility, less energy, less waste and less rework.
For the presented work the focus lies on the AFP composite manufacturing process where common manufacturing defects are investigated for their influence on the mechanical performance. These effects are caused by machine deviations, material variation and laminate designs that require ply angle transitions and consequently cutting of tows. The gap defect and the overlap defect are investigated using numerical approaches.
A multi-scale approach is exploited, which is dedicated to assess the difference in mechanical performance of “as-designed” and “as-built” structures. The effective stiffness and strength on the macro level is calculated by numerical analysis on the local level in conjunction with a homogenization.
The results give evidence that the manufacturing defects investigated have a significant effect on the stiffness and in particular the strength. A decrease in strength for the gap defect has been observed from the finite element analyses using progressive damage methods. For the overlap cases also a strength decrease has been observed which might be related to the introduced fibre misalignment.

FP7 
The Seventh Framework Programme (FP7) bundles all research-related EU initiatives together under a common roof playing a crucial role in reaching the goals of growth, competitiveness and employment.

 

 

 

 

 

   

 

 

Project partners
 
DEUTSCHES ZENTRUM FUER LUFT-UND RAUMFAHRT E.V.  
AIRBORNE TECHNOLOGY CENTER B.V.  
BOMBARDIER AEROSPACE, BELFAST  
DASSAULT SYSTEMES SA  
FASERINSTITUT BREMEN EV  
HUTCHINSON SA  
LOOP TECHNOLOGY LIMITED  
STICHTING NATIONAAL LUCHT- EN RUIMTEVAARTLABORATORIUM  
POLYWORX BV  
SAMTECH SA  
SYNTHESITES INNOVATIVE TECHNOLOGIES LTD