Understanding the influence of consolidation in automated fibre placement and its effect on design for manufacture decisions

Abstract

Automated composite manufacturing methods, such as Automated Fibre Placement (AFP), have brought many benefits to composite manufacturing. Primarily used by the aerospace industry, AFP is deployed to produce large, primary structures such as wing skins, spars, and fuselage. Today, AFP is considered a state-of-the-art technology. Nevertheless, inherent process limitations remain with the occurrences of defects during the depositing of material, hindering productivity by increasing deposition times and rework frequency.
AFP is a relatively novel and highly complex manufacturing process. To manufacture quality components with this method requires a delicate balance of input variables, material considerations, and design constraints. This manufacturing process also requires collaboration between teams of design engineers, manufacturing engineers, programmers, and highly skilled technicians. However, knowledge gaps in such a complex system can often be exploited to improve process efficiency. This thesis proposes interrogating where these knowledge gaps lay and understanding if they can be exploited for process improvements.
In Chapter 3, a systematic approach is used to present current design best practices for AFP manufacturing used in industry today. In Chapter 4, A unique knowledge capture framework is constructed to show the current gaps in AFP practitioners' understanding of the process. This examination of knowledge gaps yields multiple potential research areas to exploit. This thesis will focus on the machine-material interface. Three experimental studies are conducted to help advance the understanding of this process. In Chapter 5, the consolidation rollers lifecycle, recommended by the manufacturer, is investigated. Results from this study suggest that a roller at the end of the manufacturers recommended lifecycle becomes less susceptible to performance degradation caused by process factors such as temperature and load rate. In Chapter 6, optimal roller-tool contact is examined, and alternative manufacturing options are presented. Results from this study highlight the importance of how manufacturing process limitations constrain designs. In the final experimental Chapter, Chapter 7, presents a novel instrumented roller concept capable of live data capture.

Date of Award	9 May 2023
Original language	English
Awarding Institution	University of Bristol
Supervisor	Michael R Wisnom (Supervisor) & Carwyn Ward (Supervisor)