TY - JOUR
T1 - Optimization of process-induced residual stresses in automated manufacturing of thermoset composites
AU - Ammar, Mohamed M.A.
AU - Shirinzadeh, Bijan
AU - Zhao, Pan
AU - Shi, Yaoyao
N1 - Funding Information:
This research is supported by the Australian Research Council (ARC), through ARC Discovery Projects (DP) and ARC Linkage Infrastructure, Equipment, and Facilities (LIEF).
Publisher Copyright:
© 2022 Elsevier Masson SAS
PY - 2022/4
Y1 - 2022/4
N2 - The present study investigates the effect of automated fiber placement process on the induced residual stresses in polymer-matrix composites. The robotic fiber placement is utilized to fabricate a total of 150 flat specimens. The specimens are then cured inside an autoclave. The incremental hole-drilling method is applied to estimate the maximum stresses induced in the laminates. Further, an optimization process is conducted based on the response surface method to minimize the generated stresses, while maintaining the highest production rate. A mathematical modeling of the relationship between the process parameters and the residual stresses is generated. The statistical analysis (ANOVA test) and sensitivity analysis are conducted to evaluate the generated model. The results show considerable effect on the stresses when changing the manufacturing process parameters due to the existence of in-situ curing and the change in material porosity. The optimization strategy could significantly decrease the stresses with maximizing the fabrication speed.
AB - The present study investigates the effect of automated fiber placement process on the induced residual stresses in polymer-matrix composites. The robotic fiber placement is utilized to fabricate a total of 150 flat specimens. The specimens are then cured inside an autoclave. The incremental hole-drilling method is applied to estimate the maximum stresses induced in the laminates. Further, an optimization process is conducted based on the response surface method to minimize the generated stresses, while maintaining the highest production rate. A mathematical modeling of the relationship between the process parameters and the residual stresses is generated. The statistical analysis (ANOVA test) and sensitivity analysis are conducted to evaluate the generated model. The results show considerable effect on the stresses when changing the manufacturing process parameters due to the existence of in-situ curing and the change in material porosity. The optimization strategy could significantly decrease the stresses with maximizing the fabrication speed.
KW - Automated fiber placement (AFP)
KW - Hole-drilling method (HDM)
KW - Optimization
KW - Polymer-matrix composites
KW - Residual stresses
KW - Response surface method
UR - http://www.scopus.com/inward/record.url?scp=85125633103&partnerID=8YFLogxK
U2 - 10.1016/j.ast.2022.107443
DO - 10.1016/j.ast.2022.107443
M3 - Article
AN - SCOPUS:85125633103
SN - 1270-9638
VL - 123
JO - Aerospace Science and Technology
JF - Aerospace Science and Technology
M1 - 107443
ER -