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Design Optimization of a CFRP Wing Cover for the AFP Process

Ückert, Christian and Delisle, Dominik Peter Patrick and Bach, Tobias and Hühne, Christian and Stüve, Jan (2018) Design Optimization of a CFRP Wing Cover for the AFP Process. 6th Aircraft Structural Design Conference, 09.-11. Okt. 2018, Bristol, Großbrittanien. (Submitted)

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Abstract

The economic application of carbon fiber reinforced plastics in large-scale aerospace structures demands cost-efficient production technologies. In recent years, much progress was achieved in automation engineering, like automated fiber placement (AFP) and automated tape laying (ATL) technologies. In the design process, new methods have been established to incorporate boundary conditions of the production process. Henceforth the optimization process is not only focused on weight-reduction, but on an improved cost/weight ratio. Most research on this topic has been done in the field of conceptual design, as the highest percentage of the later arising manufacturing cost is defined by decisions made in the early design phase. But there is also a potential for reducing production cost in the detailed design phase. In the Composite Design department of the DLR Institute of Composite Structures and Adaptive Systems the detailed design of a wing cover skin section was optimized for the AFP-process. Ply shapes and ramp geometries have been modified to reduce the number of courses needed for ply-layup, and thus to reduce production time. Uncomplete courses with less than all of the available tows, as well as repeated stops and acceleration of the fiber-placement head due to unnecessary tow-cutting processes have been avoided. With these approaches the total layup time was reduced by 3,4% whereas the on-surface time of the fibre placement heads decreased by even 5% compared to the reference design, while structural weight remained constant. The optimization strategies, originally developed for the AFP-process, are also applicable to the ATL-process. The optimized design was analyzed in 3 sections and compared to the reference design for 408 combinations of longitudinal, transversal and shear loads, showing only minor differences in strength and stability.

Item URL in elib:https://elib.dlr.de/122290/
Document Type:Conference or Workshop Item (Speech)
Additional Information:Efficient Wingcover Manufacturing (EWiMa), LuFo V-1, Förderkennzeichen 20W1309B
Title:Design Optimization of a CFRP Wing Cover for the AFP Process
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Ückert, Christianchristian.ueckert (at) dlr.dehttps://orcid.org/0000-0002-3707-5642
Delisle, Dominik Peter PatrickDominik.Delisle (at) dlr.dehttps://orcid.org/0000-0002-0970-187X
Bach, TobiasTobias.Bach (at) dlr.deUNSPECIFIED
Hühne, ChristianChristian.Huehne (at) dlr.dehttps://orcid.org/0000-0002-2218-1223
Stüve, JanJan.Stueve (at) dlr.deUNSPECIFIED
Date:2018
Refereed publication:No
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Submitted
Keywords:Designoptimierung, Automated Fibreplacement, Automated Tapelaying, automatisierte Faserablage, Fertigungskosten, Fertigungszeit
Event Title:6th Aircraft Structural Design Conference
Event Location:Bristol, Großbrittanien
Event Type:international Conference
Event Dates:09.-11. Okt. 2018
Organizer:Royal Aeronautical Society
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials
Location: Stade
Institutes and Institutions:Institute of Composite Structures and Adaptive Systems > Functional Lightweight Structures
Institute of Composite Structures and Adaptive Systems > Composite Process Technology
Deposited By: Ückert, Christian
Deposited On:10 Dec 2018 06:28
Last Modified:31 Jul 2019 20:20

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