Optimisation of compaction force for automated fibre placement

Abstract

Fibre-reinforced polymer composites offer high specific strength and stiffness, and enhanced fatigue properties. They are becoming increasingly used in a variety of industries including aerospace and automotive. Thermoplastic composite materials in particular are gaining popularity as they can be manufactured without long cure cycle times and using automated technologies such as automated fibre placement (AFP). However, the quality of composite materials produced using AFP is highly dependent on the consistency of process parameters, particularly the applied compaction force. This study investigates the use of a force control unit to set and monitor the applied compaction force. AFP operational parameters (i.e. robot velocity, compaction force and damping) were optimised. Results identified that low force fluctuations could be achieved, indicating feasibility of the force control apparatus for AFP.