Simulating Layup Defects During Tow Steering In Automated Fiber Placement
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Automated Fiber Placement (AFP) offers valuable advantages which make this technology a suitable candidate for producing high-quality parts in the aerospace industry. However, there are limitations: number of defects may arise during the fiber placement including wrinkles at the inside edge, and blisters in the middle of the prepreg tows. These defects have severe effects on the layup quality and consequently, on the performance and quality of the final part. Therefore, efforts shall be pointed to avoid them. A deeper understanding of the defect formation processes as well as tools and techniques for modeling them is indispensable for fully harnessing the potential of AFP technology. In the present study, a physics-based modeling approach is presented for the global modeling of defects in AFP. The application of this approach for detecting and modeling the blisters and out-of-plane wrinkles that appear during fiber steering, is discussed, although it should be noted that the application is not limited to the case of fiber steering and can be expanded to different scenarios. Preliminary results of the simulations are presented. AFP trials are performed to validate the model. The trends and patterns of both wrinkles and blisters are found to be in good agreement with experimental results.